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Nilfisk-Advance SW4000, Service Manual

Looking for the user manual for the Nilfisk-Advance SW4000? Look no further! Download the free manual from manualshive.com and unlock the full potential of your cleaning machine. This comprehensive guide provides step-by-step instructions to help you optimize performance and get the most out of your SW4000.

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Summary of Contents for SW4000

Page 1: ...SW4000 2013 04 Form No 1464811000 Service Manual Advance SW4000 Battery 9084403010 1LO VN 6 DWWHU 1LO VN 6 3HWURO 1LO VN 6 3 GYDQFH 6 5 3 QJOLVK ...

Page 2: ...ical 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 DVKERDUG OHFWURQLF RDUG 6SHFLÀFDWLRQV 29 Wiring Diagram SW4000 Battery 31 Wiring Diagram SW4000 Petrol LPG 33 Component Locations 35 Troubleshooting 36 Dashboard Electronic Error ...

Page 3: ...nance and Adjustments 92 Troubleshooting 99 Removal and Installation 100 6SHFLÀFDWLRQV 103 Engine System LPG 104 Functional Description 104 Wiring Diagram 104 Component Locations 105 Maintenance and Adjustments 107 Troubleshooting 120 Removal and Installation 121 6SHFLÀFDWLRQV 132 Hopper System 133 Functional Description 133 Wiring Diagram 134 Hydraulic diagram 135 Component Locations 136 Maintena...

Page 4: ...leshooting 190 Removal and Installation 191 6SHFLÀFDWLRQV 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 6SHFLÀFDWLRQV 232 ...

Page 5: ... EHVW FOHDQLQJ SHUIRUPDQFH DQG D ORQJ ZRUNLQJ OLIH IRU WKH machine Please read this manual carefully before performing any maintenance and repair procedure on the machine Other Reference Manuals Model 3URGXFW RGH 8VHU 0DQXDO 6SDUH 3DUWV LVW 6 DWWHU 1LO VN 9084400010 1464809000 1464810000 6 3HWURO 1LO VN 9084401010 1464815000 1464816000 6 3 1LO VN 9084402010 SW4000 Battery Advance 9084403010 146481...

Page 6: ...G DFFHVVRULHV RQWDFW 1LOÀVN 5HWDLOHU LQGLFDWHG EHORZ IRU VHUYLFH RU WR RUGHU VSDUH SDUWV DQG DFFHVVRULHV VSHFLI LQJ WKH PD 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...

Page 7: ... 1 3DUWV XQGHU YROWDJH 3UHVHQFH RI FRUURVLYH ÀXLGV 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 6SHFLÀF ZDUQLQJV DQG F...

Page 8: ...LWK WKH KHOS RI DQ DVVLVWDQW For SW4000 Petrol LPG H FDUHIXO IXHO LV KLJKO ÁDPPDEOH R QRW VPRNH RU EULQJ QDNHG ÁDPHV LQ WKH DUHD ZKHUH WKH PDFKLQH LV UHIXHOOHG RU ZKHUH WKH IXHO is stored 5HIXHO RXWGRRUV RU LQ D ZHOO YHQWLODWHG DUHD ZLWK WKH HQJLQH RII 7XUQ RII WKH HQJLQH DQG OHW LW FRRO GRZQ IRU D IHZ PLQXWHV WKHQ UHPRYH WKH IXHO WDQN SOXJ HDYH DW OHDVW D VSDFH RI FP LQ WKH ÀOOHU WR DOORZ WKH IXH...

Page 9: ...machine moving parts 7R DYRLG DQ XQDXWKRUL HG XVH RI WKH PDFKLQH UHPRYH WKH LJQLWLRQ NH Do not leave the machine unattended without being sure that it cannot move independently R QRW XVH WKH PDFKLQH RQ VORSHV ZLWK D JUDGLHQW H FHHGLQJ WKH VSHFLÀFDWLRQV R QRW WLOW WKH PDFKLQH PRUH WKDQ WKH DQJOH LQGLFDWHG RQ WKH PDFKLQH LWVHOI LQ RUGHU WR SUHYHQW instability 8VH RQO EURRPV VXSSOLHG ZLWK WKH PDFKLQH...

Page 10: ... DQ DXWKRULVHG 6HU vice Center RU 7 EDWWHULHV RQO KHQ OHDG EDWWHULHV 7 DUH LQVWDOOHG RQ WKLV PDFKLQH GR QRW WLOW the machine more than 30 from its horizontal position to prevent the highly corrosive acid to OHDN RXW RI WKH EDWWHULHV I WKH PDFKLQH PXVW EH WLOWHG WR SHUIRUP DQ PDLQWHQDQFH SURFHGXUH remove the batteries 7KH PDFKLQH PXVW EH GLVSRVHG RI SURSHUO EHFDXVH RI WKH SUHVHQFH RI WR LF KDUPIXO ...

Page 11: ...UGV WKH ÁRRU RQO IURP SUHYHQWLQJ SRVVLEOH LQKDOLQJ Do not store the machine outdoors or near sources of heat R QRW RYHU ÀOO WKH WDQN LOO WKH WDQN VXIÀFLHQWO VR WKDW LW FDQ EH HPSWLHG E XVLQJ WKH V VWHP PSW WKH WDQN HYHU KRXUV RU RQFH D ZHHN DFFRUGLQJ WR WKH XVH I WKH PDFKLQH LV QRW XVHG IRU PRUH WKDQ RQH ZHHN HPSW WKH WDQN FRPSOHWHO DQG OHW LW GU I WKH WDQN FDQQRW EH FOHDQHG UHJXODUO FRQVLGHU XVLQ...

Page 12: ...ke pedal Parking brake lever Front skirt lifting pedal Hopper release and discharge lever Left door Right side broom Left side broom Side broom guards Battery compartment hood Can holder Rear wheels Front driving and steering wheel Front column Dust guard system water tank Dust guard system water filler neck plug Dust guard system nozzles Working lights Flashing light Safety belts Left side cover ...

Page 13: ...certification Drive pedal Rear hood with vacuum system Hopper Right door Main broom Rear wheels Dust filter container Panel filter with filter shaker Anchoring slots for transport not for lifting Electronic battery charger Anchoring slots for transport not for lifting Hopper manual returning handle Right side cover P200084 ...

Page 14: ...r optional gel batteries E attery caps for E batteries only attery connection diagram attery connector Right side broom motor circuit breaker eft side broom motor circuit breaker useholder bo Electrical component bo Drive system electronic board Hopper hydraulic lifting system control unit pen hood safety rod acuum system motor connector P200085 ...

Page 15: ...h Horn switch orward reverse gear switch Display utton orking hours attery voltage harged battery warning light green Semi discharged battery warning light yellow Discharged battery warning light red acuum system warning light green Dust guard system warning light green Hopper lifting system warning light yellow Main broom overpressure warning light red Drive system malfunction warning light red E...

Page 16: ...e pedal Parking brake lever ront skirt lifting pedal Hopper release and discharge lever eft door Right side broom eft side broom Side broom guards Engine compartment hood an holder Rear wheels ront driving and steering wheel ront column Dust guard system water tank Dust guard system water filler neck plug Dust guard system no les orking lights lashing light Safety belts eft side cover P200087 ...

Page 17: ...a conformity certification Drive pedal Rear hood with vacuum system Hopper Right door Main broom Rear wheels Dust filter container Panel filter with filter shaker Anchoring slots for transport not for lifting uel tank S Petrol Anchoring slots for transport not for lifting Hopper manual returning handle Right side cover iller plug S Petrol P200088 ...

Page 18: ...it breaker eft side broom motor circuit breaker useholder bo Electrical component bo Drive system electronic board Hopper hydraulic lifting system control unit pen hood safety rod acuum system motor connector Engine Dynamotor Right side cover atteries hoke lever P tank S P P tank fastening band S P P ad uster solenoid valve S P Engine serial number and model plate P200089 ...

Page 19: ...vacuum system switch Hopper movement enabling switch Horn switch orward reverse gear switch Display utton orking hours attery voltage acuum system warning light green Dust guard system warning light green Hopper lifting system warning light yellow Main broom overpressure warning light red Drive system malfunction warning light red Emergency push button orking light switch Hopper lifting lowering s...

Page 20: ...VLEOH QWHUQHW FRQ 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 RU DYDLODEOH DW ZZZ DGYDQFH XV FRP RU RWKHU 1LOÀVN GYDQFH ZHEVLWHV 7KH IROORZLQJ HTXLSPH...

Page 21: ...VRXUFH 9ROW EDWWHULHV Power N 9 JLUL PLQ QJLQH PRGHO Honda GX 200 7DQN FDSDFLW 2 US gal OLWUHV 3 7DQN FDSDFLW OE J 0DLQ EURRP motor power KS VSHHG 550 rpm 6LGH EURRP motor power KS VSHHG 110 rpm 9DFXXP motor power KS Drive type OHFWULF GULYH RQ IURQW ZKHHO gearmotor power KS IRUZDUG VSHHG PL K NP K UHYHUVH VSHHG PL K NP K 0D LPXP JUDGLHQW ZKHQ ZRUNLQJ 20 RSSHU K GUDXOLF FRQWURO XQLW KS LOWHU VKDNH...

Page 22: ...9LEUDWLRQ OHYHO DW WKH RSHUDWRU V ERG 62 LQ V2 P V2 LQ V2 P V2 LWK RSHUDWRU RQ ERDUG ZLWKRXW EDWWHULHV DQG ZLWK KRSSHU HPSW 0DFKLQHV KDYH EHHQ WHVWHG XQGHU WKH IROORZLQJ FRQGLWLRQV 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 3ULQW RQ WKH ÁRRU FKHFNHG RQ FHPHQW IRU HDFK VLQJOH ZKHHO Result exp...

Page 23: ...peratures 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 GUDXOLF RLO WHFKQLFDO GDWD 3 51 46 32 9LVFRVLW DW in2 V PP2 V 9LVFRVLW DW in2 V PP2 V 9LVFRVLW LQGH 150 157 ODVK SRLQW 2 3RXU SRLQW HQVLW DW OE JDO NJ O ...

Page 24: ...ene al nfo at on 24 e e an al Dimensions 1330 mm 52 4 in 1065 mm 42 in 1640 mm 64 6 in P200092 ...

Page 25: ...KHFN 6HUYLFH EUDNH FDEOH DGMXVWPHQW RSSHU GXVW OWHU FKHFN DQG FOHDQLQJ PHWKRG RSSHU K GUDXOLF OLIWLQJ V VWHP RLO OHYHO FKHFN 6NLUW KHLJKW DQG RSHUDWLRQ FKHFN XVW JXDUG V VWHP ZDWHU OWHU FKHFN DQG FOHDQLQJ RSSHU GXVW OWHU FKHFN DQG FOHDQLQJ PHWKRG LOWHU VKDNHU RSHUDWLRQ FKHFN 0DLQ EURRP GULYLQJ EHOW FKHFN UDNH DGMXVWPHQW 1XW DQG VFUHZ WLJKWHQLQJ FKHFN 6WHHULQJ FKDLQ FOHDQLQJ 6DIHW V VWHP RSHUDWLRQ ...

Page 26: ...V VWHP RSHUDWLRQ FKHFN QJLQH OWHU WUDS FOHDQLQJ QJLQH EDIÀH SODWH FOHDQLQJ XHO OWHU FOHDQLQJ UDNH SDG FKHFN DGMXVWPHQW UHSODFHPHQW RSSHU GXVW OWHU FKHFN DQG FOHDQLQJ PHWKRG 0DLQ EURRP GULYLQJ EHOW UHSODFHPHQW RSSHU JDVNHW LQWHJULW FKHFN LIWHG KRSSHU VHQVRU RSHUDWLRQ FKHFN DGMXVWPHQW XHO YDOYH OWHU FOHDQLQJ 3HWURO QJLQH SDSHU DLU OWHU UHSODFHPHQW 6SDUN SOXJ UHSODFHPHQW QJLQH LGOH VSHHG FKHFN DGMXVW...

Page 27: ...mbly 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 HQWUDO KROGHU IRU VHSDUDWLQJ ZDOO EHWZHHQ HQJLQH FRPSDUWPHQW YDFXXP V VWHP FRPSDUWPHQW DQG IRU supporting the hopper lifting linkages 1 2 3 4 P200093 ...

Page 28: ...s located on the main dashboard on the VWHHULQJ FROXPQ DQG RQ WKH VHFRQGDU GDVKERDUG EHVLGH WKH GULYHU V VHDW DQG E WKH EURRP OHYHUV RU IXQFWLRQV QRW UHTXLULQJ DQ HOHFWURQLF PDQDJHPHQW WKH VZLWFKHV RSHUDWH GLUHFWO RU E PHDQV RI UHOD V RQ WKH UHOHYDQW GULYHV RU IXQFWLRQV UHTXLULQJ WLPHUV RU HOHFWURQLF FRQWUROV WKH FRPPDQGV JHQHUDWHG ZKHQ operating the switches are read by the dashboard electronic b...

Page 29: ...SPLAY E SUHVVLQJ WKH SXVK EXWWRQ ZLWK WKH PDFKLQH UXQQLQJ 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 UHDGLQJ WKH YROWDJH GURS RQ PDLQ EURRP IXVH WKH PDLQ EURRP PRWRU DPSHUDJH 0 LV PRQLWRUHG I WKH YROWDJH GURS LV KLJKHU WKDQ P9 WK...

Page 30: ...EL ROG WKH SXVK EXWWRQ GRZQ ZKLOH you turn the key on and hold it for 5 sec The 3 LEDs will then show again the current setting with WKH FRQWLQXRXV ÁDVKLQJ RI WKH FRUUHVSRQGLQJ VHH WKH SUHYLRXV VWHS ZKLOH IXUWKHU SUHVVLQJ 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 5220 9 880 DQG 7 5 6 5 DUH...

Page 31: ...17 Water pump activation signal R PA E E E R ARD E J2 2 Vacuum system activation signal J2 4 Control panel switch power supply J1 15 Fire alarm signal J1 13 Key return J1 12 Filter shaker relay power supply J1 11 Vacuum system relay power supply J1 14 Electronic board configurator return J1 1 Electronic board power supply REVERSE GEAR BUZZER BZ1 HOPPER TEMPERATURE SENSOR S4 VACUUM SYSTEM RELAY K1 ...

Page 32: ... E S MA H E RE A MA H E RE A DR E S S EM E E R ARD E J2 7 Machine moving signal J2 10 Diagnostic warning light output J2 15 Key input POSITIVE SIGNAL FROM MACHINE ON K4 BATTERY NEGATIVE TERMINAL WORKING LIGHT L1 WORKING LIGHT L2 WORKING LIGHT SWITCH SW J2 11 Lifted hopper input B C A D E P200094B ...

Page 33: ... pump activation signal R PA E E E R ARD E J2 2 Vacuum system activation signal J2 4 Control panel switch power supply J1 15 Fire alarm signal J1 13 Key return J1 6 Fuel reserve signal J1 12 Filter shaker relay power supply J1 11 Vacuum system relay power supply J1 14 Electronic board configurator return J1 1 Electronic board power supply REVERSE GEAR BUZZER BZ1 VACUUM SYSTEM RELAY K1 FILTER SHAKE...

Page 34: ...Key input P S E S A R M MA H E A ER E A E ERM A WORKING LIGHT L1 WORKING LIGHT L2 WORKING LIGHT SWITCH SW KEY CIRCUIT FUSE F4 IGNITION KEY SW1 EMERGENCY PUSH BUTTON SW MACHINE ON RELAY K4 FRAME FR ENGINE SPARK PLUG SPK LPG SAFETY TIMER RELAY KT1 DIODE D3 LPG SAFETY SOLENOID VALVE EV1 ENGINE START ELECTROMAGNETIC SWITCH ES2 O LPG J2 11 Lifted hopper input B C A D E P200095B ...

Page 35: ...Cont ol ste 35 e e an al Component Locations Dashboard Dashboard electronic board EB2 Ignition key SW1 Dashboard electronic board EB2 Dashboard Ignition key SW1 P200096 ...

Page 36: ...G KHFN DQG UHOHDVH WKH HPHUJHQF SXVK EXWWRQ RU 6 3HWURO 3 2 8 RZ 9ROWDJH GLVSOD LQGLFDWLRQ DWWHU YROWDJH ORZHU WKDQ 9 HFUHDVH WKH PDLQ EURRP SUHVVXUH RQ WKH ÀRRU 2 8 RZ 9ROWDJH GLVSOD LQGLFDWLRQ I WKH SUREOHP SHUVLVWV LW PD EH QHFHVVDU WR FDOLEUDWH WKH HQJLQH USP VHH 3HWURO QJLQH 3 QJLQH FKDSWHU RU 6 3HWURO 3 8 LJK 9ROWDJH ÀDVKLQJ GLVSOD indication DWWHU YROWDJH KLJKHU WKDQ 9 7XUQ RII WKH HQJLQH H...

Page 37: ...al Dashboard Electronic Error Codes The drive system warning light A on the dashboard electronic board EB2 shows the error codes of the drive V VWHP HOHFWURQLF ERDUG RU WKH GHWDLOV VHH WKH KHHO 6 VWHP ULYH FKDSWHU A P200097 ...

Page 38: ...URQLF ERDUG GLDJQRVWLF VLJQDO in 9 1A EB1 J2 10 8 LIWHG KRSSHU VLJQDO in 9 ZKHQ WKH GHVFULSWLRQ LV 21 1A S1 9 OHFWURQLF ERDUG SRZHU VXSSO in 9 ZKHQ WKH GHVFULSWLRQ LV 2 3A B 10 URRP HOHFWURPDJQHWLF VZLWFK SRZHU VXSSO RXW 9 ZKHQ WKH GHVFULSWLRQ LV 2 1A 6 11 9DFXXP V VWHP UHOD SRZHU VXSSO RXW 9 ZKHQ WKH GHVFULSWLRQ LV 2 1A K1 85 12 LOWHU VKDNHU UHOD SRZHU VXSSO RXW 9 ZKHQ WKH GHVFULSWLRQ LV 2 1A K2 ...

Page 39: ...77 5 81 7 21 7KH EDWWHU ORDGLQJ VWDWXV LV GLVSOD HG E PHDQV RI V UHHQ HOORZ 5HG XS WR WKH EDWWHU W SH LQVWDOOHG 7 DV VKRZQ EHORZ 7KUHVKROG YDOXHV 7KUHVKROG YDOXHV RI FKDQJH VWDWXV 9 WROO WET 1 UHHQ HG HOORZ HG 2 HOORZ HG 5HG ÀDVKLQJ A P200247b 7KH FKDQJH VWDWXV LV ÀOWHUHG ZLWK D VHF GHOD DV UHJDUGV WR WKH EDWWHU WHQVLRQ UHDGLQJ KHQ WKUHVKROG YDOXH LV UHDFKHG WKH RXWSXW LV DXWRPDWLFDO VKXWWHG RII Z...

Page 40: ...RU PRUH WKDQ FRQVHFXWLYH PLQXWHV WKH IROORZLQJ FRQGLWLRQV 6KRZQ RQ GLVSOD DWWHU FRQGLWLRQV 6ROXWLRQ OWHUQDWLYH DFWLRQV LQ FDVH WKH VROXWLRQ GRHV QRW VROYH WKH SUREOHP 2 8 9 9 RZ 9ROWDJH YRLG XVLQJ WKH PDFKLQH IRU ORQJ SHULRGV DW PD LPXP SRZHU RU RQ VORSHV OHDYH WKH HQJLQH UXQQLQJ ZLWK DOO IHDWXUHV WXUQHG RII IRU DW OHDVW WHQ PLQXWHV DIWHU HDFK XVDJH 5HFKDUJH WKH EDWWHU ZLWK D VXLWDEOH FKDUJHU DQG ...

Page 41: ...FULSWLRQ Electronic ERDUG LQ RXW V ref PD RQQHFWHG WR 1 DVKERDUG VZLWFK SRZHU VXSSO RXW 24V 1A 6 6 2 9DFXXP V VWHP DFWLYDWLRQ VLJQDO in 9 ZKHQ WKH GHVFULSWLRQ LV 21 1A SW3 1 3 LOWHU VKDNHU DFWLYDWLRQ VLJQDO in 9 ZKHQ WKH GHVFULSWLRQ LV 21 1A SW3 3 4 DVKERDUG VZLWFK SRZHU VXSSO RXW 0V 1A SW4 ...

Page 42: ...airing B from the steering column 5 Slightly lift the steering column B by disengaging it from the lower fastener C 6 Disconnect the dust guard system quick coupling D 7 Retrieve the fairing B 8 8QGHU WKH OHIW VLGH RI WKH FRQWURO SDQHO disconnect the connectors E of the dashboard electronic board F 9 Disengage the four nuts G and remove the dashboard electronic board F Assembly 10 Assemble the com...

Page 43: ... 7KHUH LV DQ HOHFWULF ÀOWHU VKDNHU PRWRU 0 ZKLFK LV SRZHUHG E WKH UHOD DQG SURWHFWHG E WKH IXVH The relay K2 is directly controlled by the dashboard electronic board EB2 according to the information re FHLYHG E WKH YDFXXP V VWHP ÀOWHU VKDNHU VZLWFK 6 KHQ WKH EXWWRQ LV DFWLYDWHG IRU D F FOH RI VHFRQGV during which it is driven 0 5 sec ON and 0 5 sec OFF for continuously modulating the number of rev...

Page 44: ...O ÀOWHU Vacuum system motor fuse 25 A Battery 30 A Petrol LPG F1 Filter shaker motor fuse 25 A Battery 30 A Petrol LPG F2 Filter shaker motor M2 Vacuum system motor fuse 25 A Battery 30 A Petrol LPG F1 Gasket Filter shaker motor fuse 25 A Battery 30 A Petrol LPG F2 Filter shaker vacuum system switch SW3 Vacuum system motor M1 3DQHO OWHU P200103 ...

Page 45: ...SXQFWXUH WKH OWHU OHDQ WKH OWHU LQ D ZHOO YHQWLODWHG DUHD Wear appropriate dust mask to avoid breathing in dust 1 ULYH WKH PDFKLQH RQ D OHYHO ÁRRU HQJDJH WKH SDUNLQJ EUDNH DQG WXUQ WKH LJQLWLRQ NH WR µ 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 Disconnec...

Page 46: ...n side of WKH ÀOWHU LQ WKH RSSRVLWH GLUHFWLRQ RI WKH DLUÁRZ Method C 9DFXXP ORRVH GXVW IURP WKH ÀOWHU 7KHQ VRDN WKH ÀOWHU LQ ZDUP ZDWHU IRU PLQXWHV WKHQ ULQVH LW XQGHU D gentle stream of water maximum pressure 2 5 Bar HW WKH ÀOWHU GU FRPSOHWHO EHIRUH LQVWDOOLQJ LW EDFN into the machine RU D EHWWHU FOHDQLQJ LW LV DOORZHG WR ZDVK WKH ÀOWHU with water and non lathering detergents This provides better...

Page 47: ...HW LV damaged Repair replace 1R YDFXXPLQJ 7KH IXVH LV RSHQ 5HSODFH WKH IXVH 7KH VZLWFK 6 LV QRW HI FLHQW Replace 7KH UHOD LV QRW HI FLHQW Replace 7KH YDFXXP V VWHP LV EURNHQ Repair replace 7KH OWHU VKDNHU GRHV QRW RSHUDWH 7KH IXVH LV RSHQ 5HSODFH WKH IXVH 7KH OWHU VKDNHU LV GLVFRQQHFWHG RQQHFW WKH OWHU VKDNHU FRQQHFWRU 7KH VZLWFK 6 LV QRW HI FLHQW Replace 7KH UHOD LV QRW HI FLHQW Replace 7KH OWHU ...

Page 48: ...SDUNLQJ EUDNH DQG WXUQ WKH LJQLWLRQ NH WR µ 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 A P200105 ...

Page 49: ...WHU VKDNHU DVVHPEO E VOLGLQJ LW IRUZDUG disengaging it by the knobs D and then by the knobs E 8 W WKH ZRUNEHQFK UHPRYH WKH QXWV DQG UHPRYH WKH IDVWHQLQJ FODPSV RI WKH ÀOWHU VKDNHU PRWRU I Retrieve the washers J 9 5HPRYH WKH ÀOWHU VKDNHU PRWRU E GLVHQJDJLQJ WKH GRZHO IURP LWV VHDW Assembly 10 Assemble the components in the reverse order of disassembly B C B B B E F E D D K H J G I L P200106 ...

Page 50: ... 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 I WKH DPSHUDJH LV KLJKHU SHUIRUP WKH IROORZLQJ SURFHGXUHV WR GHWHFW DQG FRUUHFW LW Check that the F1 fuse is properly tightened 5HPRYH WKH HOHFWULF IDQ PRWRU VHH WKH SURFHGXUH LQ WKH QH W SDUDJUDSK DQG FKHFN WKH FRQGLWLRQ RI all its...

Page 51: ...Q WKH LJQLWLRQ NH WR µ 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 A B C B B B P200108 ...

Page 52: ...khead cap F 8 Remove the external screws G and remove the electric fan assembly H with its wiring harness E 9 I QHFHVVDU UHPRYH WKH HOHFWULF YDFXXP IDQ IURP WKH DVVHPEO DV VKRZQ EHORZ 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 L J I K J J H J H G D E F G P200109 ...

Page 53: ...al 6SHFL FDWLRQV XVW RQWURO 6 VWHP 9DOXHV SW4000 Battery 6 3HWURO 6 3 9DFXXP V VWHP PRWRU KS USP LOWHU VKDNHU PRWRU KS USP SRO HVWHU GXVW OWHU 75 ft2 P2 3DSHU GXVW OWHU 75 ft2 P2 0DLQ EURRP FRPSDUWPHQW YDFXXP 0 6 in H2 2 PP 2 2 ...

Page 54: ...SW8 which powers also the warning light A which signals the function activation on the dashboard electronic board EB2 WXUQLQJ RQ WKH VZLWFK LQ WKH SDQHO EHVLGHV WKH RSHUDWRU WKH SXPS ZKLFK LV XQGHU WKH PDFKLQH EHG FROOHFWV ZDWHU IURP WKH WDQN LQVLGH WKH IURQW FROXPQ WKURXJK WKH KRVHV WKH ZDWHU UHDFKHV WKH QR OHV ZKLFK VSUD LW on the side brooms 7KH UHOD DQG WKHQ WKH V VWHP WXUQV RQO ZKHQ WKH PDLQ ...

Page 55: ...t guard system switch SW8 Water tank 7DQN ÀOOHU Water pump M8 DWHU ÀOWHU Spraying nozzle Dust guard system fuse 5 A F5 7DQN OOHU Water tank Water pump M8 DWHU OWHU Dust guard system fuse 5 A F5 Dust guard system switch SW8 Spraying nozzle P200111 ...

Page 56: ...FKLQH RQ D OHYHO ÁRRU 2 Turn the ignition key to 0 and engage the parking brake 3 2SHUDWLQJ LQ WKH DUHD RI WKH PDFKLQH UHDFK WKH ZDWHU ÀOWHU DVVHPEO RI WKH GXVW JXDUG V VWHP 4 8QVFUHZ DQG UHPRYH WKH WUDQVSDUHQW FRYHU ZLWK WKH JDVNHW WKHQ UHPRYH WKH ÀOWHU VWUDLQHU 5 Clean and install them on the holder F 1RWH QVWDOO WKH JDVNHW DQG WKH ÀOWHU VWUDLQHU SURSHUO RQ WKH WUDQVSDUHQW FRYHU DQG RQ WKH KROGH...

Page 57: ... the parking brake 3 2Q WKH IURQW VLGH RI WKH VLGH EURRPV UHPRYH WKH ULQJ QXWV ED RQHW MRLQW 4 5HPRYH DQG FOHDQ WKH QR OHV WKH JDVNHWV DQG WKH ÀOWHUV ZLWK FRPSUHVVHG DLU 5HPRYH DQ FDOFLXP GHSRVLW I QHFHVVDU UHSODFH WKH ÀOWHUV 5 5HLQVWDOO WKH ÀOWHUV JDVNHWV DQG WKH QR OHV WKHQ IDVWHQ WKHP ZLWK WKH ULQJ QXWV B D C A A P200113 ...

Page 58: ...LWWOH ZDWHU FRPHV RXW IURP WKH VSUD QR OHV 7KH OWHU DQG RU QR OH LV FORJJHG Clean replace 7KH ZDWHU OWHU LV FORJJHG Clean replace 7KH SXPS LV QRW ZRUNLQJ Repair replace 1R ZDWHU WR WKH QR OHV 7KH ZDWHU OWHU LV FORJJHG Clean replace 7KH IXVH LV RSHQ Replace 7KH UHOD LV QRW HI FLHQW Replace ...

Page 59: ...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 2Q WKH ULJKW IURQW XSSHU VLGH RI WKH PDFKLQH EHG UHPRYH WKH IDVWHQLQJ VFUHZV DQG RI WKH GXVW guard system water pump support plate For SW4000 Battery I WKH VFUHZV DUH KLGGHQ XQGHU WKH EDWWHU WKH EDWWHU KDV WR EH UH...

Page 60: ... ZDWHU SXPS GLVFRQQHFW WKH ÀOWHU DVVHPEO LQSXW KRVH 7 Disconnect the connector F of the water pump D 8 5HPRYH WKH KROGHU DVVHPEO ZLWK SXPS DQG ÀOWHU 9 I QHFHVVDU DW WKH ZRUNEHQFK XQVFUHZ WKH IRXU VFUHZV GLVFRQQHFW WKH KRVH WKHQ UHPRYH WKH water pump D from the holder Assembly 10 Assemble the components in the reverse order of disassembly E G D C I H F P200115 ...

Page 61: ...st a ste 61 e e an al 6SHFL FDWLRQV XVW XDUG 6 VWHP 9DOXHV SW4000 Battery 6 3HWURO 6 3 DWHU WDQN FDSDFLW 86 JDO OLWHUV 3XPS 9 JSP 86 SVL 9 O PLQ EDU ...

Page 62: ...RW LQVWDOOHG WKH FRQQHFWRU 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 RU IXUWKHU GHWDLOV VHH WKH GHVFULSWLRQV RI LQGLYLGXDO VXE V VWHPV SW4000 Petrol LPG 7KH HOHFWULFDO V VWHP RI 3HWURO 3 YHUVLRQV LV VXEVWDQWLDOO HTXDO WR WKDW RI WKH EDWWHU YHUVLRQV WKH GLI ference is ...

Page 63: ...GENERAL 150 GENERAL FA 1RW UHVHWWDEOH 50 MAIN BROOM 50 MAIN BROOM FC 1RW UHVHWWDEOH 80 BATTERY DYNAMOTOR RECHARGE FR1 5HVHWWDEOH 15 RIGHT SIDE BROOM 15 RIGHT SIDE BROOM FR2 5HVHWWDEOH 15 LEFT SIDE BROOM 15 LEFT SIDE BROOM F1 1RW UHVHWWDEOH 25 VACUUM SYSTEM 30 VACUUM SYSTEM F2 1RW UHVHWWDEOH 25 FILTER SHAKER 30 FILTER SHAKER F3 1RW UHVHWWDEOH 3 KEY CIRCUIT 3 KEY CIRCUIT EV LPG F4 1RW UHVHWWDEOH 10 ...

Page 64: ...ER 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 3 6 7 5 RQO IRU 3 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...

Page 65: ...65 e e an al Wiring Diagram SW4000 Battery A ER HAR ER H WITHOUT ON BOARD BATTERY CHARGER A ER A P S E S A R M MA H E A ER E A E ERM A E R E R MA SE E R SE EMER E P SH S E S MA H E RE A MA H E RE A ASH H E P200118 ...

Page 66: ... E E SPAR P SP E E P S E S A R M MA H E A ER E A E ERM A E R SE E S EMER E P SH S MA H E RE A P SA E MER RE A D DE D P SA E S E D A E E HAR E SE E E S AR E E R MA E S H ES D AM R M E E RE A MA SE A ER A D DE D nly for P version ASH H E E E S AR E E R MA E S H ES P200119 ...

Page 67: ...sh button SW0 Battery charger CH Flashing light BE Batteries BAT Wiring harnesses Electrical component box Battery connector C1 Battery charger CH Flashing light BE Battery connector C1 Batteries BAT Emergency push button SW0 Wiring harnesses Electrical component ER P200120 ...

Page 68: ... fuse 150 A F0 Right side broom motor fuse 15 A FR1 Left side broom motor fuse 15 A FR2 SW4000 P LPG Battery charge fuse 80 A FC 8 way fuse holder SW4000 P LPG Battery charge fuse 80 A FC Main fuse 150 A F0 Right side broom motor fuse 15 A FR1 Left side broom motor fuse 15 A FR2 Main broom motor fuse 50 A FA Batteries BAT Dynamotor M5 Emergency push button SW0 Wiring harnesses Electrical component...

Page 69: ...stem motor fuse 25 A Battery 30 A Petrol LPG F1 SW4000 Battery SW4000 Petrol LPG Hopper lifting fuse 25 A F6 Hopper lifting fuse 30 A F6 Filter shaker motor fuse 25 A F2 Filter shaker motor fuse 30 A F2 Main fuse key circuit 10 A F4 Main fuse key circuit 10 A F4 Dust guard system fuse 5 A F5 Dust guard system fuse 5 A F5 Display electronic board fuse 3 A F3 Display electronic board fuse 3 A F3 Vac...

Page 70: ... GHDFWLYDWHG Battery Type Display WET or GEL AGM SW4000 Battery DFK WLPH WKH PDFKLQH LV WXUQHG RQ ZLWK WKH LJQLWLRQ NH WKH EDWWHU FKDUJH LQGLFDWRUV VKRZ WKH EDW WHU W SH DV IROORZV Battery Type ODVKLQJ SDWWHUQ WET ÀDVKHV RI WKH 5 ZDUQLQJ OLJKW GEL AGM ÀDVKHV RI WKH 5 1 ZDUQLQJ OLJKW On Board Battery Charger Setting SW4000 Battery EXTERNAL 6 7 17 51 36 7 6 CHARGING CURVES DIP1 DIP2 DIP3 DIP4 DIP5 D...

Page 71: ... WKH EDWWHULHV DUH ODUJHU WKDQ WKH FRQWDLQHU XVH WKH VTXDUH JXLGHV VXSSOLHG ZLWK WKH PDFKLQH WR HQVXUH WKH 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 th...

Page 72: ...lding it for about 5 until the ZDUQLQJ OLJKW FRUUHVSRQGLQJ WR WKH FXUUHQW VHWWLQJ ÁDVKHV 5HG ZDUQLQJ OLJKW 7 EDWWHULHV UHHQ ZDUQLQJ OLJKW 0 EDWWHULHV 11 Release and press again the push button G within 5 seconds to change setting 12 DLW XQWLO WKH ZDUQLQJ OLJKW FRUUHVSRQGLQJ WR WKH QHZ VHWWLQJ VWRSV ÁDVKLQJ VHFRQGV DSSUR 13 The new setting is properly stored 14 Set the type of batteries WET or GEL ...

Page 73: ... 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 KHFN WKDW 7 EDWWHU FDSV DUH FORVHG WR SUHYHQW WKH KLJKO FRUURVLYH DFLG IURP OHDNLQJ RXW RI WKH batteries 8 LWK WKH KHOS RI DQ DVVLVWDQW DQG DQ DSSURSULDWH KRLVWLQJ V VWHP UHPRYH WKH EDWWHULHV...

Page 74: ... compartment hood with the handle and fasten it with the support rod 4 Check the voltage at the battery pins 5 LWK WKH DFFHVVRULHV WXUQHG RII DQG WKH HQJLQH UXQQLQJ WKH YROWDJH PXVW EH EHWZHHQ 9 DQG 9 6 I WKH YROWDJH LV ORZHU FKHFN WKH GLRGH HOHFWURQLF ERDUG DQG EDWWHU RSHUDWLRQ I QHFHVVDU charge the batteries with a battery charger suitable for cars slow charging ...

Page 75: ...KDNHU PRWRU IXVH GLVSOD HOHFWURQLF ERDUG IXVH PDLQ IXVH NH FLUFXLW GXVW JXDUG V VWHP IXVH KRSSHU OLIWLQJ IXVH 12 Reinstall the fuse box cover A 13 5HPRYH WKH VFUHZV WKHQ UHPRYH WKH electrical component box cover I 14 KHFN UHSODFH WKH IROORZLQJ IXVHV PDLQ EURRP PRWRU IXVH PDLQ IXVH 15 Place the cover I and tighten screws Fuse Check 16 KHFN RQH RI WKH IROORZLQJ IXVHV IRU GHDFWLYDWLRQ 5 ULJKW VLGH EU...

Page 76: ...WRU IXVH GLVSOD HOHFWURQLF ERDUG IXVH PDLQ IXVH NH FLUFXLW GXVW JXDUG V VWHP IXVH KRSSHU OLIWLQJ IXVH 6 Reinstall the fuse box cover A 7 5HPRYH WKH VFUHZV WKHQ UHPRYH WKH electrical component box cover I 8 KHFN UHSODFH WKH IROORZLQJ IXVHV PDLQ EURRP PRWRU IXVH PDLQ IXVH EDWWHU IXVH 9 Place the cover I and tighten screws Fuse Check 10 KHFN RQH RI WKH IROORZLQJ IXVHV IRU GHDFWLYDWLRQ 0 5 ULJKW VLGH ...

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Page 78: ...connect the battery connector 4 Remove the screws A and the battery charger connector B 5 5HPRYH WKH VFUHZV RQ WKH UHDU VLGH RI WKH EXONKHDG WKHQ UHPRYH WKH EDWWHU FKDUJHU SURWHFWLRQ 6 Remove the screws with the nut E and remove the battery charger F with the wiring harness G Assembly 7 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ 7KH VHOHFWRU PXVW EH WXUQHG WR ...

Page 79: ...rtment hood with the handle and fasten it with the support rod Disconnect the batteries 4 5HPRYH WKH PDFKLQH ULJKW VLGH EXONKHDG E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 5 Remove the two screws A and remove the case B 6 I QHFHVVDU FOHDQ WKH H WHUQDO VLGH RI WKH G QDPRWRU LQ WKH DUHD RI WKH SURWHFWLRQ EDQG 7 Disengage the cam lever E and remove the protection band D of the dynamotor C B A C ...

Page 80: ...WKHLU KRXVLQJV E GLVHQJDJLQJ WKHP IURP WKH UHWDLQLQJ springs I 10 KHFN WKH IRXU FDUERQ EUXVKHV IRU ZHDU 7KH FDUERQ EUXVKHV DUH ZRUQ ZKHQ 7KH FRQWDFW ZLWK WKH PRWRU DUPDWXUH LV LQVXIÀFLHQW The contact surface is not integral The stroke is less than 0 12 in 3 mm The spring is broken Q WKLV FDVHV UHSODFH DOO DOO G QDPRWRU FDUERQ EUXVKHV Assembly 11 Assemble the components in the reverse order of disa...

Page 81: ... Dynamotor Carbon Brushes Check Replacement 3 ROG WKH FUDQNVKDIW E RSHUDWLQJ WKH RXWHU SXOOH LQ WKH DUHD ORRVHQ WKH ORFN QXW XQWLO LW LV ÁXVK 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 5HPRYH WKH VFUHZ LQ WKH DUHD 1 ...

Page 82: ...LV FRQGLWLRQ JLYH D ÀUP EORZ RQ WKH QXW LQ WKH GLUHFWLRQ RI WKH DUURZ ZLWK D SODVWLF PDOOHW WKHUHE GLVHQJDJLQJ WKH FRQLFDO FRQQHFWLRQ RI XQLRQ between dynamotor and the engine 8 RRVHQ WKH QXW FRPSOHWHO DQG UHPRYH WKH G QDPRWRU 0 QDPRWRU ZHLJKW NJ DSSUR Assembly 9 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ 7KH VHOI ORFNLQJ QXW PXVW EH IXOO VFUHZHG GRZQ ZLWKRXW ...

Page 83: ...S DE R M RESE SE R E S DE R M RESE SE R D S ARD P MP SE H PPER P MP SE D S ARD P MP RE A A M S S EM RE A A M S S EM M R ER SHA ER M R H PPER P MP M R R H S DE R M M R E S DE R M M R D S ARD P MP M R MA R M M R ER SHA ER RE A H PPER RE A A H PPER ER RE A MA R M SE A A P S E S A R M MA H E A ER E A E ERM A M1 M2 M3 M6 M7 M8 M4 P200127A ...

Page 84: ... SE ER SHA ER A M S S EM S H S H R H A M S S EM RE A ER SHA ER RE A H PPER RE A A H PPER ER RE A S DE R M RE A D S ARD P MP RE A H R S H S D S ARD S H S MA R M E E R MA E S H ES H PPER SE S R S MA R M E ER SE S R S S DE R M E ER SE S R S H PPER ER S H S H PPER E A S H S D E A A P S E S A R M MA H E A ER E A E ERM A P200127B ...

Page 85: ...R C1 CONNECTOR C1 MAIN FUSE F FLASHING LIGHT BE LINE ELECTR SWITCH ES LINE ELECTROMAGNETIC SWITCH ES KEY CIRCUIT FUSE F4 EMERGENCY PUSH BUTTON SW IGNITION KEY SW1 DRIVER S SEAT SAFETY MICROSWITCH SW WORKING LIGHT L1 WORKING LIGHT L2 DRIVING WHEEL ACCELERATOR PEDAL R1 MACHINE ON RELAY K4 MACHINE ON RELAY K4 WORKING LIGHT SWITCH SW FORWARD REVERSE GEAR SWITCH SW2 DRIVE SYSTEM ELECTRONIC BOARD EB1 B ...

Page 86: ...USE F5 HOPPER PUMP FUSE F6 DUSTGUARD PUMP RELAY K6 VACUUM SYSTEM RELAY K1 VACUUM SYSTEM MOTOR DYNAMOTOR M5 ENGINE ON RELAY K4 FILTER SHAKER MOTOR HOPPER PUMP MOTOR RIGHT SIDE BROOM MOTOR LEFT SIDE BROOM MOTOR DUSTGUARD PUMP MOTOR MAIN BROOM MOTOR FILTER SHAKER RELAY K2 MAIN BROOM FUSE FA MAIN FUSE F 24V BATTERY BAT DIODE D1 HOPPER LOWERING RELAY K3B HOPPER LIFTING RELAY K3A B C A F POSITIVE SIGNAL...

Page 87: ...D SE ER SHA ER A M S S EM S H S H R H A M S S EM RE A ER SHA ER RE A S DE R M RE A D S ARD P MP RE A H R S H S D S ARD S H S MA R M E E R MA E S H ES H PPER SE S R S MA R M E ER SE S R S S DE R M E ER SE S R S H PPER ER S H S H PPER E A S H S H PPER ER RE A H PPER RE A A D E A A P S E S A R M MA H E A ER E A E ERM A P2001272B ...

Page 88: ...A E E E R S H ES E E E R MA E S H ES E R SE E S EMER E P SH S DR ER S SEA SA E M R S H S R H R H DR HEE A E ERA R PEDA R MA H E RE A P SA E MER RE A D DE D P SA E S E D A E E E E S AR E E R MA E S H ES nly for P version R H S H S R ARD RE ERSE EAR S H S DR E S S EM E E R ARD E D E A RAME R A ER E E SPAR P SP E E M0 P2001272C ...

Page 89: ...GWK KHLJKW LQ PP DWWHU SDFN 9 7 DWWHU SDFN 9 7 DWWHU SDFN 9 0 9 6L H OHQJWK ZLGWK KHLJKW LQ PP DWWHU FRPSDUWPHQW PD LPXP VL H ZLGWK OHQJWK KHLJKW LQ PP DWWHU FKDUJHU 9DOXHV SW4000 Battery QSXW 9 PD 2XWSXW 24V 30A I FLHQF 90 0LQ 9EDWW 2V DVLQJ SURWHFWLRQ IP30 DWWHULHV 9DOXHV 6 3HWURO 6 3 DWWHU SDFN 9 K 6L H OHQJWK ZLGWK KHLJKW LQ PP OHFWULFDO FRPSRQHQWV 9DOXHV SW4000 Battery 6 3HWURO 6 3 Dynamotor ...

Page 90: ...ectrical system 7KH IXHO WDQN LV IDVWHQHG RXWVLGH WKH HQJLQH LQ WKH rear side of the machine The tank has a fuel level in GLFDWRU ZLWK ÁRDW DQG D YDOYH ZLWK LQWHJUDWHG ÀOWHU The choke lever on the engine has been extended in RUGHU WR EH HDVLO DFWLYDWHG IURP WKH GULYHU V VHDW SR sition The fuel reserve warning light turns on when the fuel in the tank is less than 2 2 liters The engine is equipped w...

Page 91: ...ent Locations Petrol engine Filler neck Fuel tank Fuel opening closing valve Reserve sensor S5 Diode S1 Oil Alert Sensor Fuel tank Diode S1 Filler neck Petrol engine Reserve sensor S5 Fuel opening closing valve Oil Alert Sensor P200129 ...

Page 92: ...JLQH VSHHG XVH WKH LQGLFDWRU IDVWHQHG WR WKH HQJLQH SXOOH ZLWK D UHY FRXQWHU OLJKW 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 RU WKH HQJLQH USP VHH 6SHFLÀFDWLRQV SDUDJUDSK A A D B P200130 ...

Page 93: ... ÀOWHUV FOHDQ WKHP DV VKRZQ EHORZ 3DSHU ÀOWHU LW WKH ÀOWHU VHYHUDO WLPHV DJDLQVW D KDUG VXUIDFH WR UHPRYH WKH GXVW RU blow compressed air no more than 207 kPa NJI FP IURP LQVLGH WKH ÀOWHU R QRW XVH D EUXVK RWKHUZLVH WKH ÀEUH ZLOO EH GDPDJHG RDP ÀOWHU OHDQ ZLWK ZDUP ZDWHU DQG VRDS ULQVH DQG OHW LW GU FRPSOHWHO RU FOHDQ ZLWK D QRQ ÁDPPDEOH VROYHQW DQG OHW LW GU 6RDN WKH ÀOWHU LQ FOHDQ HQJLQH RLO WKH...

Page 94: ...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 5HPRYH WKH RLO ÀOOHU SOXJ GLSVWLFN DQG FOHDQ it 6 QVHUW WKH RLO ÀOOHU SOXJ GLSVWLFN LQ WKH ÀOOHU QHFN EXW GR QRW WLJKWHQ LW WKHQ UHPRYH LW WR FKHFN the oil level 7 If the oil level is near or under the lower limit PDUN RQ WKH GLSVWLFN WRS XS Z...

Page 95: ...4 Lift and disassemble the right side bulkhead 5 5HPRYH WKH RLO ÀOOHU SOXJ GLSVWLFN 3ODFH WKH KRVH LQ D SRVLWLRQ WKDW HDVHV WKH RLO GUDLQ 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 3RXU QHZ RLO LQ WKH ÀOOHU QHFN XS WR WKH XSSHU OLPLW PDUN ORZHU HGJH RI ...

Page 96: ...king 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 0RYH WKH IXHO OHYHU WR 2 WKHQ UHPRYH WKH IXHO ÀOWHU FXS DQG WKH 2 ULQJ 6 DVK WKH IXHO ÀOWHU WUDS DQG WKH 2 ULQJ ZLWK D QRQ ÁDPPDEOH VROYHQW WKHQ GU WKHP DFFXUDWHO 7 3ODFH WKH 2 ULQJ DQG DVVHPEOH WKH ÀOWHU FXS E WLJKWHQLQJ LW ...

Page 97: ...the electrode is worn 8 Measure the distance between the spark plug electrodes with a feeler gauge Correct the distance by bending carefully the side electrode C The distance between the electrodes must be of 0 70 0 80 mm 9 QVWDOO WKH VSDUN SOXJ PDQXDOO ZLWK JUHDW FDUH to avoid tightening it improperly 10 2QFH WKH VSDUN SOXJ LV LQ SODFH WLJKWHQ LW ZLWK D proper wrench to press the sealing washer 1...

Page 98: ...ide bulkhead 5 Remove the screws A and carefully remove silencer guard B 6 Remove the screws C and remove the exhaust manifold D 7 Remove the screws E and carefully remove silencer guard F 8 5HPRYH WKH VFUHZ DQG UHPRYH WKH EDIÁH plate H from the silencer 9 Use a brush to remove the carbon deposits from WKH EDIÁH SODWH VKLHOG 7DNH FDUH QRW WR FDXVH GDPDJH WR WKH VKLHOG 5HSODFH WKH EDIÁH SODWH LI it...

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Page 100: ... hood with the handle and fasten it with the support rod Disconnect the batteries 4 5HPRYH WKH PDFKLQH ULJKW VLGH EXONKHDG E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 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 GLVFRQQHFWHG ÀWWLQJV WR SUHYHQW IRUHLJQ PDWHULDOV IURP HQWHULQJ LQWR WKH V VWHP 7 Open the clamp E fastening t...

Page 101: ...the engine holder M 12 Remove the fastening screws and then remove the case N 13 LVHQJDJH WKH HQJLQH RLO GUDLQ KRVH 3 IURP WKH IDVWHQLQJ FODPSV 4 14 3ODFH D SURSHU DQG VDIH OLIWLQJ EHOW 5 WUDQVYHUVDOO RQ WKH ÁDQJH 6 DV VKRZQ LQ WKH ÀJXUH WKH EHOW 5 have to slide smoothly along the dynamotor 15 LWK D SURSHU KRLVWLQJ V VWHP FDUHIXOO OLIW WKH G QDPRWRU DVVHPEO DQG OHW LW VZLQJ VOLJKWO WR DYRLG WKH RE...

Page 102: ...agraph 2 Remove the dynamotor unit see the procedure in Electrical System paragraph 3 5HPRYH WKH VFUHZV DQG VHSDUDWH WKH HQJLQH DVVHPEO IURP WKH KROGHU QJLQH ZHLJKW NJ approx 4 I QHFHVVDU XQVFUHZ WKH WKUHH VFUHZV DQG UHPRYH WKH DLU GHÁHFWRU IURP WKH HQJLQH Assembly 5 Assemble the components in the reverse order of disassembly B D E A A C P200139 ...

Page 103: ...H VWURNH 12 in3 LQ FP3 PP 0D LPXP RXWSXW N 36 DW PLQ USP 0D WRUTXH OEI LQ USP PLQ 1 P NJI P DW PLQ USP QJLQH RLO TXDQWLW JDO 86 OLWHUV RROLQJ V VWHP Forced air 6WDUWLQJ V VWHP 7UDQVLVWRU PDJQHW 372 VKDIW URWDWLRQ RXQWHU FORFNZLVH LVWDQFH EHWZHHQ WKH VSDUN SOXJ HOHFWURGHV LQ PP GOH VSHHG PLQ USP 9DOYH FOHDUDQFH FROG 17 LQ PP 867 LQ PP XHO 8QOHDGHG IXHO 8 6 3XPS RFWDQH QXPEHU QRW OHVV WKDQ FHSW LQ W...

Page 104: ... ÀOWHU LQ WKH VROHQRLG YDOYH WKXV UHDFKLQJ WKH SUHVVXUH UH ducer The IMPCO T60 A NN 2 two phase pressure reducer ORZHUV WKH JDV SUHVVXUH ZKLFK WKHQ UHDFKHV WKH FDU burettor The LPG system is protected against any overpres sure by a relief valve which activates at 27 atm 400 PSI The fuel reserve warning light turns on when the sensor in the power supply system detects a pres sure lower than 1 1 bar...

Page 105: ...cations LPG tank fastening band LPG tank 3 WDQN ÀWWLQJ LPG tank opening closing valve Hose Pipe Safety valve Diode D3 LPG tank WWLQJ LPG tank LPG tank fastening band Hose LPG tank opening closing valve Safety valve Pipe P200141 Diode D3 ...

Page 106: ...ns Continues LPG wiring harness Engine Hose LPG pressure regulator Hose 6ROHQRLG YDOYH ZLWK ÀOWHU 9 Pressure valve reserve S4 LPG wiring harness Solenoid valve ZLWK OWHU 9 Pressure valve reserve S4 Engine Hose LPG pressure regulator P200141 2 ...

Page 107: ...QH VSHHG XVH WKH LQGLFDWRU IDVWHQHG WR WKH HQJLQH SXOOH ZLWK D UHY FRXQWHU OLJKW 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 RU WKH HQJLQH USP VHH 6SHFLÀFDWLRQV SDUDJUDSK A A D B P200130 ...

Page 108: ...OWHUV FOHDQ WKHP DV VKRZQ EHORZ 3DSHU ÀOWHU LW WKH ÀOWHU VHYHUDO WLPHV DJDLQVW D KDUG VXUIDFH WR UHPRYH WKH GXVW RU blow compressed air no more than 207 kPa NJI FP IURP LQVLGH WKH ÀOWHU R QRW XVH D EUXVK RWKHUZLVH WKH ÀEUH ZLOO EH GDPDJHG RDP ÀOWHU OHDQ ZLWK ZDUP ZDWHU DQG VRDS ULQVH DQG OHW LW GU FRPSOHWHO RU FOHDQ ZLWK D QRQ ÁDPPDEOH VROYHQW DQG OHW LW GU 6RDN WKH ÀOWHU LQ FOHDQ HQJLQH RLO WKHQ ...

Page 109: ... 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 5HPRYH WKH RLO ÀOOHU SOXJ GLSVWLFN DQG FOHDQ it 6 QVHUW WKH RLO ÀOOHU SOXJ GLSVWLFN LQ WKH ÀOOHU QHFN EXW GR QRW WLJKWHQ LW WKHQ UHPRYH LW WR FKHFN the oil level 7 If the oil level is near or under the lower limit PDUN RQ WKH GLSVWLFN WRS XS ZLWK...

Page 110: ...Lift and disassemble the right side bulkhead 5 5HPRYH WKH RLO ÀOOHU SOXJ GLSVWLFN 3ODFH WKH KRVH LQ D SRVLWLRQ WKDW HDVHV WKH RLO GUDLQ 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 3RXU QHZ RLO LQ WKH ÀOOHU QHFN XS WR WKH XSSHU OLPLW PDUN ORZHU HGJH RI WK...

Page 111: ...electrode is worn 8 Measure the distance between the spark plug electrodes with a feeler gauge Correct the distance by bending carefully the side electrode C The distance between the electrodes has to be of 0 70 0 80 mm 9 QVWDOO WKH VSDUN SOXJ PDQXDOO ZLWK JUHDW FDUH to avoid tightening it improperly 10 2QFH WKH VSDUN SOXJ LV LQ SODFH WLJKWHQ LW ZLWK D proper wrench to press the sealing washer 11 ...

Page 112: ...e bulkhead 5 Remove the screws A and carefully remove silencer guard B 6 Remove the screws C and remove the exhaust manifold D 7 Remove the screws E and carefully remove silencer guard F 8 5HPRYH WKH VFUHZ DQG UHPRYH WKH EDIÁH plate H from the silencer 9 Use a brush to remove the carbon deposits from WKH EDIÁH SODWH VKLHOG 7DNH FDUH QRW WR FDXVH GDPDJH WR WKH VKLHOG 5HSODFH WKH EDIÁH SODWH LI it c...

Page 113: ...ance or replacement SURFHGXUH LQYROYLQJ RSHUDWLRQV RQ WKH ÀWWLQJV RU PRYHPHQW RI 3 V VWHP FRPSRQHQWV FKHFN IRU 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 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW to disengage it from the fasteners 5 I WKH HQJLQH LV KRW ZDLW W...

Page 114: ...OYH WKHQ FKHFN IRU 3 JDV OHDNV VKRZQ E JDV EXEEOH GHYHORSPHQW RQ DOO 3 V VWHP ÀWWLQJV VWDUWLQJ IURP 3 WDQN ÀWWLQJ WR WKH VROHQRLG YDOYH 9 7XUQ WKH LJQLWLRQ NH WR WKH ÀUVW SRVLWLRQ µ WKHQ FKHFN IRU 3 JDV OHDNV VKRZQ E JDV EXEEOH GHYHORSPHQW RQ DOO 3 V VWHP ÀWWLQJV VWDUWLQJ IURP WKH VROHQRLG YDOYH WR WKH ÀWWLQJ 10 Q FDVH 3 OHDNV DUH GHWHFWHG LW LV QHFHVVDU WR RSHQ WKH UHOHYDQW ÀWWLQJV PDQDJH WKHP DV...

Page 115: ...n 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 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 5 Turn the fasteners and remove the machine right door 6 I WKH HQJLQH LV KRW ZDLW WKDW LW FRROV GRZQ 7 8QVFUHZ WKH ÀWWLQJ DXWLRQ RU GLVDVVHPEO DVVHPEO...

Page 116: ...move the fastening screws G of the pressure regulator assembly with valves H 11 Remove the pressure regulator assembly with valves H 12 W WKH ZRUNEHQFK UHPRYH WKH 7µ ÀWWLQJ IURP WKH ÀWWLQJ 13 5HPRYH WKH ÀWWLQJ IURP WKH ÀWWLQJ 0 RI WKH VROHQRLG YDOYH 1 G H N M L I P200144 ...

Page 117: ... 15 8QVFUHZ WKH VROHQRLG YDOYH ÀWWLQJ 0 16 5HPRYH WKH ÀOWHU KROGHU 4 QVLGH WKH ÀOWHU KROGHU WKHUH LV D F OLQGHU ZLWK PDJQHW 5 ZKLFK ZLOO EH FOHDQHG DQG SODFHG LQ WKH ORZHU VLGH RI WKH ÀOWHU KROGHU LWVHOI DV VKRZQ LQ WKH ÀJXUH 7KH ÀOWHU KROGHU JDVNHW 6 KDV WR EH UHSODFHG ZLWK WKH FRUUHVSRQGLQJ VSDUH SDUW EHIRUH UHDVVHPEO M P M Q Q R S N P200229 ...

Page 118: ...G WKH ÀWWLQJ 0 ZLWK FRPSUHVVHG DLU PD LPXP SUHVVXUH DU I QHFHVVDU UHSODFH WKH ÀOWHU 7 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ 2Q WKH VROHQRLG YDOYH WLJKWHQ WKH ÀWWLQJ 0 DW WKH WLJKWHQLQJ WRUTXH RI DSSUR LPDWHO 1P in Lbs 20 Perform t...

Page 119: ...ORZLQJ SURFHGXUH 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 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 6 Remove the sealant from the housing A of the LPG pressure regulator B 7 Restart checking and adjusting the engine CO2 HPLVVLRQV WKHQ DGMXVW WK...

Page 120: ... 3 VDIHW UHOD 7 LV IDXOW Replace 7KH EDWWHULHV DUH GLVFKDUJHG 5HFKDUJH ZLWK D SURSHU EDWWHU FKDUJHU 7KH HPHUJHQF SXVK EXWWRQ KDV EHHQ SUHVVHG KHFN DQG UHOHDVH WKH HPHUJHQF SXVK EXWWRQ 7KH HQJLQH ORVHV SRZHU RU VWRSV GXULQJ RSHUDWLRQ 7KH OWHU HOHPHQW RU HOHPHQWV DUH FORJJHG OHDQ RU UHSODFH WKH OWHU HOHPHQWV 3RRU TXDOLW SRZHU VXSSO 5HSODFH WKH WDQN 7KH IXHO OWHU LV FORJJHG WKH FDUEXUHWWRU LV EURNHQ ...

Page 121: ...1 HIRUH RSHUDWLQJ RQ WKH 3 V VWHP IRU PDLQWHQDQFH UHSODFHPHQW RI SDUWV EOHHG WKH 3 V VWHP DV 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 b...

Page 122: ...ically according to the law in force 7KH KRVH KDV WR EH RI D VSHFL F OHQJWK LQ RUGHU WR FRPSO ZLWK WKH VDIHW 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 5HPRYH WKH ...

Page 123: ... HTXLSSHG ZLWK IDVWHQLQJ EDQGV Assembly 8 HIRUH WLJKWHQLQJ WKH ÀWWLQJV FOHDQ WKHP DFFXUDWHO DQG UHSODFH WKH LQQHU JDVNHWV 9 HIRUH VFUHZLQJ GRZQ WKH ÀWWLQJV FDUHIXOO UHPRYH DQ UHPDLQLQJ RI VHDODQW WKHQ DSSO WKH QHZ VHDODQW XVH 37 E 857 VD HVWR 3 1 6 RU HTXLYDOHQW 3URFHHG DFFRUGLQJ WR WKH instructions on the package of the product 10 HIRUH WLJKWHQLQJ WKH ÀWWLQJV FOHDQ WKHP DFFXUDWHO DQG UHSODFH WKH ...

Page 124: ...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 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 5 Turn the fasteners and remove the machine right door 6 I WKH HQJLQH LV KRW ZDLW WKDW LW FRROV GRZQ 7 8QVFUHZ WKH ÀWWLQ...

Page 125: ...HPRYH WKH ÀWWLQJ IURP WKH ÀWWLQJ 13 8QVFUHZ WKH ÀWWLQJ IURP WKH SUHVVXUH UHJXODWRU 14 I QHFHVVDU XQVFUHZ WKH ÀWWLQJV DQG 0 IURP WKH SUHVVXUH UHJXODWRU 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 I D QHZ SUHVVXUH UHJXODWRU KDV EHHQ LQVWD...

Page 126: ...the parking brake 3 Open the engine compartment hood with the handle and fasten it with the support rod 4 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 5 Turn the fasteners and remove the machine right door 6 I WKH HQJLQH LV KRW ZDLW WKDW LW FRROV GRZQ 7 Disconnect the electrical connections A 8 8QVFUHZ WKH SUHVVXUH YDOYH ZKLOH KROGLQJ WKH ÀWWLQJ DXWLRQ RU GLVDV...

Page 127: ...G 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 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 5 Turn the fasteners and remove the machine right door 6 I WKH HQJLQH LV KRW ZDLW WKDW LW FRROV GRZQ 7 8QVFUHZ WKH ÀWWLQJ ...

Page 128: ... pressure regulator assembly with valves H 12 W WKH ZRUNEHQFK UHPRYH WKH 7µ ÀWWLQJ IURP WKH ÀWWLQJ 13 5HPRYH WKH VROHQRLG YDOYH IURP WKH ÀWWLQJ 14 8QVFUHZ WKH ÀWWLQJ IURP WKH VROHQRLG YDOYH 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 G H D F J...

Page 129: ... brake 4 Open the engine compartment hood with the handle and fasten it with the support rod 5 Disconnect the batteries 6 5HPRYH WKH PDFKLQH ULJKW ERG VLGH E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 7 LVFRQQHFW WKH 3 KRVH IURP WKH FDUEXUHWWRU DV VKRZQ LQ 3 6 VWHP RVH DQG LWWLQJ Disassembly Assembly LPG ORVH ZLWK VHDOLQJ SOXJV WKH GLVFRQQHFWHG ÀWWLQJV WR SUHYHQW IRUHLJQ PDWHULDOV IURP HQWHULQJ...

Page 130: ... engine holder M 12 Remove the fastening screws and then remove the case N 13 LVHQJDJH WKH HQJLQH RLO GUDLQ KRVH 3 IURP WKH IDVWHQLQJ FODPSV 4 14 3ODFH D SURSHU DQG VDIH OLIWLQJ EHOW 5 WUDQVYHUVDOO RQ WKH ÁDQJH 6 DV VKRZQ LQ WKH ÀJXUH WKH EHOW 5 have to slide smoothly along the dynamotor 15 LWK D SURSHU KRLVWLQJ V VWHP FDUHIXOO OLIW WKH G QDPRWRU DVVHPEO DQG OHW LW VZLQJ VOLJKWO WR DYRLG WKH REVWD...

Page 131: ...aph 2 Remove the dynamotor unit see the procedure in Electrical System paragraph 3 5HPRYH WKH VFUHZV DQG VHSDUDWH WKH HQJLQH DVVHPEO IURP WKH KROGHU QJLQH ZHLJKW NJ approx 4 I QHFHVVDU XQVFUHZ WKH WKUHH VFUHZV DQG UHPRYH WKH DLU GHÁHFWRU IURP WKH HQJLQH Assembly 5 Assemble the components in the reverse order of disassembly B D E A A C P200139 ...

Page 132: ...JLQH RQO LQ PP LVSODFHPHQW ERUH VWURNH 12 in3 LQ FP3 PP 0D LPXP RXWSXW N 36 DW PLQ USP 0D WRUTXH OEI LQ USP PLQ 1 P NJI P DW PLQ USP QJLQH RLO TXDQWLW JDO 86 OLWHUV RROLQJ V VWHP Forced air 6WDUWLQJ V VWHP 7UDQVLVWRU PDJQHW 372 VKDIW URWDWLRQ RXQWHU FORFNZLVH LVWDQFH EHWZHHQ WKH VSDUN SOXJ HOHFWURGHV LQ PP GOH VSHHG PLQ USP 9DOYH FOHDUDQFH FROG 17 PP 867 PP XHO 3 WDQN 6SDUN SOXJ 35 6 1 35 8 162 ...

Page 133: ...LRQ VHQVRU 6 SURYLGHV LWV VLJQDO WR WKH GDVKERDUG electronic board EB2 and to the drive system electronic board EB1 in order to obtain the following automat LF IXQFWLRQV 5HGXFWLRQ RI PDFKLQH PD LPXP VSHHG E HOHFWURQLF ERDUG DFWLYDWLRQ RI WKH EX HU DQG KRSSHU OLIWLQJ ZDUQLQJ OLJKW VZLWFKLQJ RII RI WKH YDFXXP V VWHP PRWRU 0 DQG RI WKH EURRP PRWRUV 0 0 0 E HOHFWURQLF ERDUG W GLIIHUHQW KHLJKWV RI WKH ...

Page 134: ...wer supply DISPLAY ELECTRONIC BOARD FUSE F3 HOPPER ENABLING SWITCH SW4 HOPPER PUMP FUSE F6 HOPPER PUMP MOTOR HOPPER LIFTING RELAY K3A HOPPER LOWERING RELAY K3B HOPPER LIFTING RELAY K3A HOPPER LOWERING RELAY K3B HOPPER LIFTING SENSOR S1 HOPPER LIFTING LOWERING SWITCH SW5 DRIVE SYSTEM ELECTRONIC BOARD EB1 LINE ELECTROMAGNETIC SWITCH ES POSITIVE SIGNAL FROM MACHINE ON K4 BATTERY NEGATIVE TERMINAL M3 ...

Page 135: ...o e ste 135 e e an al Hydraulic diagram UP HYDRAULIC CILINDER VALVE LOCK HIGH PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE HYDRAULIC POWER UNIT DOWN P200152 ...

Page 136: ...Hopper movement enabling switch SW4 Hopper lifting lowering switch SW5 Closed hopper sensor S1 Hopper linkages Hopper Hopper lifting system warning light Closed hopper sensor S1 Hopper Hopper movement enabling switch SW4 Hopper lifting lowering switch SW5 Hopper linkages P200153 ...

Page 137: ...lic hoses Hydraulic cylinder Hydraulic control unit Hydraulic oil tank Hopper lifting fuse 25 A Battery 30 A Petrol LPG F6 Hydraulic cylinder Check valve Hydraulic hoses Hydraulic control unit Hydraulic oil tank Hopper lifting fuse 25 A Battery 30 A Petrol LPG F6 P200154 ...

Page 138: ...G VLGH E OLIWLQJ LW WR 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 I QHFHVVDU DGG RLO WKURXJK WKH SOXJ XVH WKH RLO VSHFLÀHG LQ 7HFKQLFDO DWD SDUDJUDSK Warning Hydraulic system oil is highly corrosive Warning The hydraulic system oil should be disposed of properly according to the Law in force 6 2...

Page 139: ...KHLJKW RI PP 7KH KRSSHU GRHV QRW JLYH D VLJQDO RI EHLQJ FORVHG 7KH VHQVRU 6 LV PLVDGMXVWHG RU EURNHQ GMXVW UHSODFH 7KH KRSSHU GRHV QRW OLIW 7KH K GUDXOLF V VWHP RLO OHYHO LV LQFRUUHFW KHFN WKH K GUDXOLF V VWHP RLO OHYHO LQ WKH WDQN 7KH KRSSHU GRHV QRW ORZHU Q FDVH RI ORZ WHPSHUDWXUHV WKH K GUDXOLF V VWHP RLO LV VORZ LQ ÀRZLQJ WKURXJK WKH VDIHW YDOYH DLW D IHZ PRPHQWV WR OHW WKH K GUDXOLF V VWHP RL...

Page 140: ...ery connector SW4000 Battery Disconnect the batteries SW4000 Petrol LPG 4 2Q WKH ULJKW UHDU XSSHU VLGH RI WKH PDFKLQH UHPRYH WKH FRQQHFWRU RI WKH FORVHG KRSSHU VHQVRU 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IR...

Page 141: ... LW GXULQJ WKH GLVDVVHPEO 5 Turn the ignition key to 0 6 2Q WKH OHIW VLGH RI WKH KRSSHU UHPRYH WKH VFUHZ DQG UHWULHYH WKH FRPSRQHQWV 7 Turn the lever E to rest position 8 7KH VLGH ÁDQJH IRU KRSSHU DGMXVWPHQW PXVW EH OHIW LQ LWV RULJLQDO SRVLWLRQ I QHFHVVDU LW ZLOO EH 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...

Page 142: ...QJH LV SHUIRUPHG E SODFLQJ WKH 9µ JURRYH DW R FORFNµ WKXV engaging the notch M on the tooth N of the hopper housing A 14 7R DGMXVW WKH KRSSHU DOLJQPHQW Perform steps 2 to 5 Remove the screw C and retrieve the components D 5HPRYH WKH VFUHZ 3 DQG UHPRYH WKH ÁDQJH IURP LWV KRXVLQJ WKHQ LQVHUW LW DJDLQ DIWHU WXUQLQJ LW DV QHFHVVDU WR UHVWRUH WKH DOLJQPHQW HDFK QRWFK FRUUHVSRQGV LQ QHJDWLYH RU SRVLWLYH...

Page 143: ... 3 Engage the parking brake 4 Ensure that the hopper is closed 5 2Q WKH XSSHU DUHD RI WKH ULJKW KRSSHU DUP UHPRYH WKH FRWWHU SLQ DQG WKH SLQ 6 0RYH WKH K GUDXOLF F OLQGHU URG IRUZDUG XQWLO LW LV ÁXVKHG ZLWK WKH PDFKLQH FKDVVLV 7 2Q WKH XSSHU DUHD RI WKH OHIW KRSSHU DUP UHPRYH WKH QXW DQG WKH VFUHZ WKHQ UHWULHYH WKH components G C E D G E B F A G P200158 ...

Page 144: ...DUW RI WKH KRSSHU DUPV DV VKRZQ LQ WKH ÀJXUH RSSHU ZHLJKW ZLWK OLIWLQJ DUPV NJ 9 Remove the side screws I and remove the rotating pins J 10 LWK D SURSHU KRLVWLQJ V VWHP UHPRYH WKH KRSSHU ZLWK OLIWLQJ DUPV E PRYLQJ LW EDFNZDUGV DQG lifting it Assembly Assemble the components in the reverse order of disassembly L H L J K I P200159 ...

Page 145: ...e 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 5HPRYH WKH PDFKLQH ULJKW VLGH EXONKHDG E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 6 Disconnect the vacuum system motor connector B 7 Disengage the retainers C and remove the vacuum system hood D C D C C C A...

Page 146: ...c hoses H from the hydraulic unit F Retrieve the gaskets I I QHFHVVDU FROOHFW WKH K GUDXOLF V VWHP RLO LQ D SURSHU FRQWDLQHU 3OXJ WKH GLVFRQQHFWHG ÀWWLQJV WR SUHYHQW GHEULV IURP HQWHULQJ LQWR WKH K GUDXOLF V VWHP Warning Hydraulic system oil is highly corrosive Warning The hydraulic system oil should be disposed of properly according to the Law in force I G G F H H I G G F H H F E G H I I I P20023...

Page 147: ...hydraulic control unit F Assembly 12 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ IWHU WKH LQVWDOODWLRQ RI WKH K GUDXOLF XQLW HLWKHU WKH VDPH XQLW RU D QHZ RQH ÀOO WKH WDQN ZLWK K GUDXOLF RLO XS WR WKH 0D OHYHO WKHQ UXQ VRPH KRSSHU KDQGOLQJ WKH K GUDXOLF V VWHP LV VHOI EOHHG LQJ WKHQ FKHFN WKH K GUDXOLF V VWHP RLO OHYHO F F J K F P200161 ...

Page 148: ... and engage the parking brake 4 Open the battery engine compartment hood with the handle and fasten it with the support rod 5 5HPRYH WKH PDFKLQH ULJKW VLGH EXONKHDG E OLIWLQJ LW WR GLVHQJDJH LW IURP WKH IDVWHQHUV 6 Remove the hollow screws B and disconnect the hydraulic hoses C from the hydraulic unit D Retrieve the gaskets A E B B A C C E B B A C C A B C E E E C P200160 ...

Page 149: ...e 7 Open the fastening clamps F and the hoses C 8 8QVFUHZ WKH FRQQHFWLQJ ÀWWLQJV RI WKH K GUDXOLF F OLQGHU KRVHV Collect the hydraulic system oil in a proper container 9 Retrieve the hydraulic hoses C Assembly 10 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ IWHU WKH LQVWDOODWLRQ RI WKH KRVHV HLWKHU WKH VDPH KRVHV RU QHZ RQHV ÀOO WKH WDQN ZLWK K GUDXOLF RLO XS WR...

Page 150: ...GLVFRQQHFWHG ÀWWLQJV WR SUHYHQW GHEULV 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 Remove the screw D and remove the lower pin E of the cylinder 8 Remove the cotter pin and the upper pin F of the cylinder 9 Remove the cylinder C Assembly 10 Assemble the compo...

Page 151: ...3DUNHU 6 9 0D LPXP SUHVVXUH SVL DU 2LO WDQN FDSDFLW 86 JDO OLWHUV GUDXOLF FLUFXLW WRWDO FDSDFLW 86 JDO OLWHUV 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 GUDXOLF RLO WHFKQLFDO GDWD 3 51 46 32 9LVFRVLW DW in2 V PPð V 9LVFRVLW DW in2 V PPð ...

Page 152: ...pt o essor es 152 Ser e S Optional and Accessories HVFULSWLRQ OOXVWUDWLRQ 867 8 5 6 67 0 7 6HH XVW XDUG 6 VWHP FKDSWHU 6 7 7 7 522 29 5 7 ...

Page 153: ... 1 7 7 7KH ZRUNLQJ OLJKW NLW LPSURYHV YLVLELOLW LQ GDUN HQYLURQPHQWV 7KH KHDGOLJKWV DUH LQVWDOOHG XQGHU WKH FKDVVLV LQ WKH IURQW VLGH RI WKH VZHHSHU 7KH NLW LQFOXGHV RQH VZLWFK 6 WR WXUQ WKH OLJKWV RQ RQH KROGHU ZLWK WZR 9 KHDGOLJKWV DQG WKH ZLULQJ KDUQHVV 6 5220 8 5 7 ...

Page 154: ...Description The steering wheel is fastened to the steering column and connected to a shaft with a cardan joint 7KH PRYHPHQW LV WUDQVPLWWHG ZLWK SLQLRQ DQG FKDLQ WR WKH ULQJ JHDU ZKLFK GHWHUPLQHV WKH VWHHULQJ 7KH ULQJ gear is fastened to the driving wheel ...

Page 155: ...Ser e S Component Locations Steering wheel Steering column Cardan joint Steering shaft Steering assembly Steering chain Steering chain Steering shaft Steering wheel Steering assembly Cardan joint Steering column P200165 ...

Page 156: ...ut B and remove the washer C 5 LWK D VXLWDEOH SXOOHU UHPRYH WKH VWHHULQJ ZKHHO XVLQJ WKH VXUIDFH RI WKH VWHHULQJ VKDIW DQG WKH WKUHDGHG KROHV RI WKH VWHHULQJ ZKHHO RU LWV ORZHU HGJH LQ FDVH WKH ORZHU HGJH LV XVHG LQVHUW PHWDO SODWHV EHWZHHQ WKH HGJH DQG WKH SXOOHU LQ RUGHU WR GLVWULEXWH WKH ORDG DQG SUHYHQW GDPDJH WR WKH lower edge G itself Assembly 6 Assemble the components in the reverse order o...

Page 157: ...ont 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ R QRW OXEULFDWH WKH FKDLQ RWKHUZLVH GXVW DQG GHEULV ZLOO VWLFN WR WKH OXEULFDQW A B C P200167 ...

Page 158: ...Steer System 158 Ser e S Steering Assembly Removal Installation 1 5HIHU WR WKH SURFHGXUH ULYLQJ KHHO DQG 6WHHULQJ 8QLW LVDVVHPEO VVHPEO ...

Page 159: ...r PDWLRQ UHFHLYHG E VHQVRU 6 PDLQ EURRP FRQWURO OHYHU SRVLWLRQ PDFKLQH PRYLQJ VLJQDO LQIRUPDWLRQ WKDW UHFHLYHV IURP OLIWHG KRSSHU VLJQDO EDWWHU YROWDJH VHH DVKERDUG OHFWURQLF RDUG 6SHFLÀFDWLRQV step d 7KH IXVH DFWLYDWHV LQ FDVH RI VKRUW FLUFXLW RU EORFNHG URWRU EXW LQ FDVH RI RYHUORDG WKH GDVKERDUG HOHF WURQLF ERDUG UHDGV WKH YROWDJH GURS RQ WKH IXVH WKXV GHDFWLYDWLQJ 6 EHIRUH WKH IXVH FDQ DFWLYDW...

Page 160: ...rload warning light Main broom height adjusting knob Main broom motor fuse 50A FA Front skirt lifting pedal Main broom Main broom overload warning light Front skirt lifting pedal Main broom lifting lowering lever Main broom motor fuse 50A FA Main broom Main broom height adjusting knob P200236 ...

Page 161: ...om motor M4 Motor pulley Right side skirt Broom pulley Device to adjust the parallelism between the PDLQ EURRP DQG WKH ÁRRU Lowered main broom enabling sensor S2 Rear skirt Front skirt Driving belt Broom pulley Right side skirt Device to adjust the parallelism between the main broom and WKH ÀRRU Left side skirt Motor pulley Main broom motor M4 P200169 ...

Page 162: ...VH WKH SULQW OHQJWK WXUQ WKH NQRE counter clockwise WR GHFUHDVH WKH SULQW OHQJWK OLIW WKH EURRP with the lever and then turn the knob clock wise 1RWH 7KH NQRE FDQ EH XVHG ERWK WR DGMXVW WKH SULQW DQG WR DGMXVW WKH EURRP DFFRUGLQJ WR WKH bristle wear 3 Perform step 1 again to check that the main broom is at the correct distance from the ground 4 When the broom is too worn and can no ORQJHU EH DGMXV...

Page 163: ...WKH EURRP OHIW VLGH DQG DGMXVW LW WR WKH ULJKW VLGH DV IROORZV Lift the lever E to lower the left side of the broom Lower the lever E to lift the left side of the broom KHQ WKH DGMXVWPHQW LV FRPSOHWHG WLJKWHQ WKH ORFNQXWV 9 Perform step 1 again to check that the main broom is at the correct distance from the ground 10 I QHFHVVDU DGMXVW WKH WUDQVPLVVLRQ FDEOH DGMXVWHU D E C D C P200170 ...

Page 164: ...eplacing 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...

Page 165: ... WKH ÀJXUH XULQJ DVVHPEO HQVXUH WKDW WKH EURRP KH DJRQDO PHVK ÀWV LQWR WKH UHOHYDQW GULYH KXE 10 QVWDOO WKH EURRP FRPSDUWPHQW ODWFK QVXUH WKDW LWV IDVWHQHUV DUH SURSHUO ÀWWHG LQ WKH KRXVLQJV 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 KHFN DQG LI QHFHVVDU DGMXVW WKH P...

Page 166: ... 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 KHFN WKDW WKH GLVWDQFH IURP WKH JURXQG RI WKH VLGH VNLUWV LV PP I QHFHVVDU...

Page 167: ...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 KHFN WKDW WKH IURQW VNLUW DQG UHDU VNLUW VOLJKWO UXE WKH ÁRRU ZLWKRXW EHLQJ GHWDFKHG IURP LW VHH the diagram I Reassembly 10 Assemble the components in the reverse order of disassembly 2 8 1 4 C D G H I F P200172 ...

Page 168: ...ZQ WKHQ UHSODFH WKH IXVH 7KH HOHFWURPDJQHWLF VZLWFK 6 LV QRW HI FLHQW Replace 7KH GULYLQJ EHOW LV PLVDGMXVWHG GDPDJHG EURNHQ 7LJKWHQ UHSODFH 7KH PRWRU 0 LV IDXOW KHFN WKH PRWRU DPSHUDJH UHSODFH 7KH VHQVRU LV PLVDGMXVWHG RU EURNHQ GMXVW UHSODFH 7KH PDLQ EURRP KDV QRW EHHQ SURSHUO DGMXVWHG LQ KHLJKW SDUDOOHOLVP GMXVW 7KH PDLQ EURRP GRHV QRW clean properly 7KH PDLQ EURRP LV WRR ZRUQ RXW Replace 7KH V...

Page 169: ...ners 4 9LVXDOO LQVSHFW WKH HQWLUH OHQJWK RI WKH EHOW WR PDNH VXUH LW LV LQWDFW DQG VKRZV QR VLJQV RI FXWV WHDUV RU FUDFNV LI QHFHVVDU UHSODFH LW Replacement 5 RRVHQ WKH VFUHZV DQG WKHQ ORRVHQ WKH EHOW E WXUQLQJ WKH PRWRU DVVHPEO 6 Remove the belt A 7 Install the new belt A 8 7LJKWHQ WKH EHOW DV QHFHVVDU E WXUQLQJ WKH PRWRU DVVHPEO WKHQ WLJKWHQ WKH VFUHZV DQG D Reassembly 9 Install the machine righ...

Page 170: ...l 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 6FUHZ GRZQ WKH NQREV ZLWKRXW WLJKWHQLQJ WKHP 9 Check...

Page 171: ...JDJH WKH FOLS WKHQ GLVFRQQHFW WKH WHUPLQDO RI WKH 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 W WKH ZRUNEHQFK XQVFUHZ WKH VL QXWV DQG UHPRYH WKH VHFWLRQ EDU DQG WKH VWUDS 0 16 Retrieve the front skirt N 17 Install the front skirt N in the reverse order of disassembly...

Page 172: ... rod under the lifted hopper 21 Q WKH KRSSHU FRPSDUWPHQW UHPRYH WKH QXWV 3 DQG WKHQ UHPRYH WKH VWUDS 4 DQG WKH VNLUW 5 22 Q WKH PDLQ EURRP FRPSDUWPHQW UHPRYH WKH VWUDS 6 DQG UHPRYH WKH VNLUW 7 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 P S Q R T P200174 ...

Page 173: ...broom 4 Place wedges A on the rear wheels of the machine 5 LWK D SURSHU KRLVWLQJ V VWHP DSSOLHG WR WKH PDFKLQH FKDVVLV WR WKH IURQW ZKHHO DUHD OLIW WKH PDFKLQH D IHZ FHQWLPHWUHV LQ RUGHU WR OHW WKH IURQW ZKHHO WXUQ IUHHO ZLWKRXW WRXFKLQJ WKH ÁRRU 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 moto...

Page 174: ...WLJKWHQHG Check the motor carbon brushes see the procedure in Main Broom Motor Carbon Brush Check Re placement I QHFHVVDU GLVDVVHPEOH WKH PRWRU VHH SURFHGXUH LQ WKH QH W SDUDJUDSK DQG FKHFN WKH FRQGLWLRQ RI all its components I WKH DERYH PHQWLRQHG SURFHGXUHV GR QRW OHDG WR D FRUUHFW DPSHUDJH WKH PRWRU PXVW EH UHSODFHG VHH the procedure in the next paragraph Reassembly 9 Install the right side broo...

Page 175: ...e 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 C B A P200176 ...

Page 176: ...tection band D 5 Remove the fastening screws F of the electrical connections of the four carbon brushes G 6 5HPRYH WKH IRXU FDUERQ EUXVKHV IURP WKHLU KRXVLQJV E GLVHQJDJLQJ WKHP IURP WKH UHWDLQLQJ springs H 7 KHFN WKH FDUERQ EUXVKHV IRU ZHDU 7KH FDUERQ EUXVKHV DUH ZRUQ ZKHQ 7KH FRQWDFW ZLWK WKH PRWRU DUPDWXUH LV LQVXIÀFLHQW The contact surface is not integral The stroke is less than 0 12 in 3 mm T...

Page 177: ...motor belt see the procedure in Driving Belt Visual Inspection and Replacement 2 KLOH NHHSLQJ WKH SXOOH ORFNHG UHPRYH WKH VFUHZ DQG UHWULHYH WKH ZDVKHU 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 C B A E D C A P200178 ...

Page 178: ...elt Visual Inspection and Replacement 4 KLOH NHHSLQJ WKH SXOOH ORFNHG UHPRYH WKH VFUHZ DQG UHWULHYH WKH ZDVKHUV DQG 5 Remove the pulley A and retrieve the spacer E and the key F 6 3XVK WKH DVVHPEO LQVLGH WKH PDFKLQH DQG WKHQ UHWULHYH LW 7 Q WKH KRSSHU FRPSDUWPHQW UHPRYH WKH VQDS ULQJ 8 2Q WKH PDFKLQH RXWHU VLGH ZLWK D SURSHU SDG DQG D PDOOHW SXVK WKH EHDULQJV RXWVLGH WKHLU KRXVLQJV Assembly 9 Asse...

Page 179: ...oom 2 Lift the hopper to the end of stroke Warning Place a safety rod under the lifted hopper 3 Q WKH KRSSHU FRPSDUWPHQW UHPRYH WKH QXW ZKLOH NHHSLQJ WKH GULYH KXE ORFNHG 0 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 ...

Page 180: ...oisting system 2 Remove the main broom 3 LWK WKH NQRE ORZHU WKH PDLQ EURRP XQWLO WKH HQG RI VWURNH 4 Use the lever B to lower the main broom 5 Q WKH OHIW IURQW ORZHU VLGH RI WKH PDFKLQH XQVFUHZ WKH QXW DQG GLVFRQQHFW WKH JURPPHW RI WKH main broom lifting control cable E from the pin A B D E C E D C P200217 ...

Page 181: ...d 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ 7R SODFH WKH VFUHZV EDFN LQ WKH KRXVLQJ 2 WKH VFUHZ ZLWK QXW PXVW EH WXUQHG WR SRVLWLRQ 3 W...

Page 182: ... 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 I QHFHVVDU GUDLQ WKH ZDWHU IURP WKH WDQN LQ WKH VWHHULQJ FROXPQ WKURXJK WKH ÀOOHU QHFN 9 2Q WKH UHDU VLGH RI WKH VWHHULQJ FROXPQ UHPRYH WKH VFUHZV 10 Turn the knob F counter clockwise until its screw G is removed ...

Page 183: ...from the housing with cut N 14 Remove the pin P 15 Q WKH OHIW IURQW ORZHU VLGH RI WKH PDFKLQH XQVFUHZ WKH QXW 4 DQG GLVFRQQHFW WKH JURPPHW 5 RI WKH 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 M L K I N P U T S R Y S S V S W P200181 ...

Page 184: ...the main broom lifting lowering lever to working position lowered broom 23 Remove the machine right door by turning the relevant fasteners 24 GMXVW WKH QXW ORFNQXW DGMXVWHU 7 WR UHDFK RQ WKH PDFKLQH ULJKW VLGH D GLVWDQFH RI PP IURP the main broom shaft centre to the ground IWHU DGMXVWLQJ WLJKWHQ WKH QXW ORFNQXW DGMXVWHU 7 25 GMXVW WKH VDPH GLVWDQFH RI PP IURP WKH PDLQ EURRP VKDIW FHQWUH WR WKH JUR...

Page 185: ...HOHFWULFDO FDEOH IURP LWV IDVWHQHUV WKHQ GLVFRQQHFW WKH UHOHYDQW FRQQHFWRU 5 Retrieve the proximity sensor B with the electrical cable Assembly and Adjustment 6 3ODFH WKH HQDEOLQJ VHQVRU DQG FRQQHFW LWV FRQQHFWRU WKHQ HQJDJH WKH ZLULQJ KDUQHVV IURP LWV fasteners 7 6FUHZ GRZQ WKH ORFNQXW ZLWKRXW WLJKWHQLQJ LW 8 Turn the main broom lifting lowering lever to lower the broom 9 GMXVW WKH GLVWDQFH EHWZH...

Page 186: ...room System 186 Ser e S 6SHFL FDWLRQV 0DLQ URRP 6 VWHP 9DOXHV SW4000 Battery 6 3HWURO 6 3 0DLQ EURRP VL H OHQJWK GLDPHWHU LQ PP 0DLQ EURRP PRWRU KS 550 rpm DV VSULQJ SUHVVXUH 4 W OE 1 ...

Page 187: ...KH UHOD DQG SURWHFWHG E WKH UHVHWWDEOH IXVHV 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 CONTROL PANEL ELECTRONIC BOARD EB2 J1 1 Electronic board power supply J1 9 Electronic board power supply SIDE BROOM RELAY K5 RIGHT SIDE BROOM RESET FUSE FR1 LEFT SIDE BROOM RESET FUSE FR2 D...

Page 188: ... broom Lowered right side broom enabling sensor S3 Left side broom motor fuse 15 A FR1 Right side broom motor fuse 15 A FR2 Lowered side broom enabling sensor S3 Broom height adjusting ring nuts Side broom lifting lowering lever Side broom motor M6 M7 Side broom Left side broom motor fuse 15 A FR1 Right side broom motor fuse 15 A FR2 P200185 ...

Page 189: ...ording to the following procedure 2 Engage the parking brake 3 Turn the ignition key to 0 4 Turn the fasteners and remove the left or right door 5 RU WKH ULJKW VLGH EURRP RSHUDWH RQ WKH LGOH gear by loosening the ring nut C and by adjusting the adjuster D until the correct print A is achieved Finally lock the adjuster D into position with the ring nut C RU WKH OHIW VLGH EURRP RSHUDWH RQ WKH LGOH J...

Page 190: ... LV H FHVVLYHO ZRUQ Replace 7KH VLGH EURRPV GR QRW ZRUN 7KH VHQVRU LV PLVDGMXVWHG RU EURNHQ GMXVW UHSODFH 7KH PRWRU 0 RU 0 LV IDXOW KHFN WKH PRWRU DPSHUDJH UHSODFH 7KHUH DUH URSHV RU GHEULV UHVWUDLQLQJ WKH EURRP URWDWLRQ Remove and clean 7KH VLGH EURRP IXVH 5 RU 5 LV RSHQ DLW IRU WKH VLGH EURRP PRWRU WR FRRO GRZQ WKHQ UHVHW WKH IXVH E SUHVVLQJ WKH UHOHYDQW SXVK EXWWRQ 7KH UHOD LV QRW HI FLHQW Repl...

Page 191: ...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 5HPRYH WKH VLGH EURRP IRUP WKH KXE DQG UHWULHYH WKH SURWHFWLRQ ÁDQJH Assembly 6 QVWDOO WKH SURWHFWLRQ ÁDQJH RQ WKH KXE DQG WKH VLGH EURRP 7 Insert the p...

Page 192: ...LVWLQJ V VWHP DSSOLHG WR WKH PDFKLQH FKDVVLV WR WKH IURQW ZKHHO DUHD OLIW WKH PDFKLQH D IHZ FHQWLPHWUHV LQ RUGHU WR OHW WKH IURQW ZKHHO WXUQ IUHHO ZLWKRXW WRXFKLQJ WKH ÁRRU 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 ...

Page 193: ...procedure in Side Broom Motor Carbon Brush Check Re placement I QHFHVVDU GLVDVVHPEOH WKH PRWRU VHH SURFHGXUH LQ WKH QH W SDUDJUDSK DQG FKHFN WKH FRQGLWLRQ RI all its components I WKH DERYH PHQWLRQHG SURFHGXUHV GR QRW OHDG WR D FRUUHFW DPSHUDJH WKH PRWRU PXVW EH UHSODFHG VHH the procedure in the relevant paragraph Reassembly 7 Install the side broom of the relevant motor 8 Remove the front hoisting...

Page 194: ... 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 B C A P200189 ...

Page 195: ...emove the cap C by disengaging the carbon brushes inside the motor armature 5 QVLGH WKH FDS GLVFRQQHFW WKH FRQQHFWLRQV DQG UHPRYH WKH FDUERQ EUXVKHV ZLWK ZLULQJ KDUQHVV 6 KHFN WKH FDUERQ EUXVKHV IRU ZHDU 7KH FDUERQ EUXVKHV DUH ZRUQ ZKHQ 7KH FRQWDFW ZLWK WKH PRWRU DUPDWXUH LV LQVXIÀFLHQW The contact surface is not integral The stroke is less than 0 12 in 3 mm The spring is broken Q WKLV FDVHV UHSOD...

Page 196: ...assembly 1 I SRVVLEOH SODFH WKH PDFKLQH RQ D KRLVWLQJ V VWHP 2 Remove the relevant side broom 3 ERYH WKH VLGH EURRP PRWRU UHPRYH WKH VFUHZ ZLWK QXW DQG UHOHDVH WKH JURPPHW RI WKH FDEOH to be removed 4 Unscrew the locknut E and remove the cable C from the cut D D E C B A P200191 ...

Page 197: ... RI 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ GMXVW WKH SRVLWLRQ RI QXWV ORFNQXWV DQG XQWLO WKH SURSHU VLGH EURRP KHLJKW LV UHDFKHG E keeping the adjusters J in an intermediate position J J G F C C H I C E P200192 ...

Page 198: ...H VHQVRU HOHFWULFDO FDEOH IURP LWV IDVWHQHUV WKHQ GLVFRQQHFW WKH UHOHYDQW FRQQHFWRU 5 Retrieve the enabling sensor B with the electrical cable Assembly and Adjustment 6 3ODFH WKH HQDEOLQJ VHQVRU DQG FRQQHFW LWV FRQQHFWRU WKHQ HQJDJH WKH ZLULQJ KDUQHVV IURP LWV fasteners 7 6FUHZ GRZQ WKH ORFNQXW ZLWKRXW WLJKWHQLQJ LW 8 Turn the side broom lifting lowering lever to lower the brooms 9 GMXVW WKH GLVWD...

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Page 202: ...the forward reverse gear switch SW2 2WKHU LQSXWV RI WKH HOHFWURQLF ERDUG DUH WKH GULYHU V VHDW PLFURVZLWFK 6 DQG WKH OLIWHG KRSSHU VHQ sor S1 signal The drive system is inhibited when the microswitch SW7 does not detect the operator on WKH GULYHU V VHDW EXW ZKHQ WKH VHQVRU 6 GHWHFWV WKDW WKH KRSSHU LV OLIWHG WKH PD LPXP PDFKLQH VSHHG LV GHFUHDVHG WR D VDIHW YDOXH VHH SDUDPHWHU LQ ULYH 6 VWHP OHFWU...

Page 203: ... output J2 12 Driver s seat microswitch input J2 5 Not used must be shorted to BAT J2 14 Auxiliary power supply for switches J2 13 Reverse gear button input J2 1 Potentiometer positive power supply J2 2 Potentiometer input J2 3 Potentiometer negative power supply 24V BATTERY BAT MAIN FUSE F REVERSE GEAR BUZZER BZ1 LINE ELECTROMAGNETIC SWITCH ES LINE ELECTROMAGNETIC SWITCH ES DRIVER S SEAT SAFETY M...

Page 204: ...stem malfunction warning light ULYHU V VHDW VDIHW PLFURVZLWFK 6 Service brake pedal Parking brake lever Drive pedal R1 Drive system malfunction warning light Service brake pedal Parking brake lever Forward reverse gear switch SW2 Drive pedal R1 Driver s seat safety microswitch SW7 P200197 ...

Page 205: ...ent Locations Continues Driving wheel M0 Disc brake Drive system electronic board EB1 Main fuse 150 A F0 5HYHUVH JHDU EX HU Driving wheel M0 Drive system electronic board EB1 Disc brake Main fuse 150 A F0 P200242 Reverse gear buzzer BZ1 ...

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Page 212: ...lacing opposite wedges on the rear wheels 3 6WHHU WKH IURQW ZKHHO WR WKH ULJKW DERXW 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 5HPRYH WKH EUDNH GLVF I QHFHVVDU UHWULHYH WKH UHOHYDQW NH 9 Remove the inner pad L H F F I L H ...

Page 213: ...mbly Assembly Continues 10 I QHFHVVDU VHSDUDWH WKH RXWHU SDG 0 IURP WKH EUDFNHW 1 DV VKRZQ EHORZ Disengage the retaining ring O and remove the spring P 5HPRYH WKH EUDFNHW 1 DQG WKH OHYHU 4 Retrieve the washer R Retrieve the inner pad M O P Q R M N N O P M Q P200199 ...

Page 214: ...ntil the bracket G comes into contact with the brake disc I and ZLWK WKH LQQHU SDG WKHQ XQVFUHZ WKH QXWV IRU RI D WXUQ WKXV JLYLQJ D PP FOHDUDQFH EH tween the brake disc I and the pads L and M Also check the parallelism of the bracket G with WKH À HG SDUW E HTXDWLQJ WKH WZR SRUWLRQV 1 Screw down and tighten the nuts E 12 Adjust the brake according to the following procedure F F E E I G F F N N N M...

Page 215: ...he rear wheels 3 5HPRYH WKH OHIW VLGH EURRP LI HTXLSSHG 4 6WHHU WKH IURQW ZKHHO WR WKH ULJKW DERXW 5 Unscrew nut and locknut B then remove the brake cable C from the brackets D 6 8QGHU WKH EUDNH SHGDO ORRVHQ WKH QXW ORFNQXW RI WKH EUDNH FDEOH 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 E B D C...

Page 216: ...VVLEOH 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 VKRZQ LQ WKH ÀJXUH 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 HIRUH VWDUWLQJ WR RSHUDWH RQ WKH EUDNLQJ PDVVHV FK...

Page 217: ...IURQW ZKHHO WXUQ IUHHO ZLWKRXW WRXFKLQJ WKH ÁRRU 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 LWK WKH KHOS RI DQ DVVLVWDQW FDUHIXOO SUHVV RQ WKH GULYHU V VHDW WR DFWLYDWH WKH PLFURVZLWFK WKHQ WXUQ on the drive system at the maximum speed and check that the driving wheel amperage is...

Page 218: ...t paragraph I QHFHVVDU GLVDVVHPEOH WKH GULYH V VWHP PRWRU VHH WKH SURFHGXUH LQ ULYLQJ KHHO DQG 6WHHULQJ 8QLW LVDVVHPEO VVHPEO SDUDJUDSK DQG FKHFN WKH FRQGLWLRQ RI DOO LWV FRPSRQHQWV I WKH DERYH PHQWLRQHG SURFHGXUHV GR QRW OHDG WR FRUUHFW UHDGLQJV IRU WKH GULYLQJ ZKHHO DPSHUDJH WKH driving wheel must be replaced see the procedure in Driving Wheel and Steering Unit Disassembly Assembly paragraph Rea...

Page 219: ...arking brake 3 Open the battery engine compartment hood Disconnect the battery connector SW4000 Battery Disconnect the batteries SW4000 Petrol LPG 4 5HPRYH LQ VHTXHQFH HDFK RI WKH IRXU FDUERQ EUXVKHV RI WKH GULYH V VWHP PRWRU DV VKRZQ EHORZ Remove the cover A bayonet joint Remove the O ring B Loosen the screws C Remove the carbon brush with the spring D D C B A P200202 ...

Page 220: ...Q EUXVKHV RI WKH GULYH PRWRU DV VKRZQ EHORZ Loosen the two screws E Remove the lateral cover F Loosen the screws G Remove the carbon brushes with the spring H 7 KHFN WKH WZR FDUERQ EUXVKHV IRU ZHDU 7KH FDUERQ EUXVKHV DUH ZRUQ ZKHQ 7KH FRQWDFW ZLWK WKH PRWRU DUPDWXUH LV LQVXIÀFLHQW The contact surface is not integral The stroke is less than 0 47 in 12 mm The spring is broken Q WKLV FDVHV UHSODFH DO...

Page 221: ...cannot move by placing opposite wedges A on the rear wheels 3 LWK D SURSHU KRLVWLQJ V VWHP DSSOLHG WR WKH PDFKLQH FKDVVLV WR WKH IURQW ZKHHO DUHD OLIW WKH PDFKLQH D IHZ FHQWLPHWUHV LQ RUGHU WR UHDFK WKH UXEEHU ULQJ DQG UHPRYH LW 4 6WHHU WKH IURQW ZKHHO WR WKH ULJKW DERXW 5 Unscrew nut and locknut C then remove the brake cable D from the brackets E Retrieve the spring F E D C B A F P200203 ...

Page 222: ...emove the rubber ring N from the reduction unit P Assembly 11 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ 7R HDVH WKH LQVWDOODWLRQ RI WKH UXEEHU ULQJ 1 RQ WKH UHGXFWLRQ XQLW 3 VOLJKWO KLW WKH VLGH HGJH RI 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 a...

Page 223: ... battery connector SW4000 Battery Disconnect the batteries SW4000 Petrol LPG 4 LWK D SURSHU KRLVWLQJ V VWHP DSSOLHG WR WKH PDFKLQH FKDVVLV WR WKH IURQW ZKHHO DUHD OLIW WKH PDFKLQH D IHZ FHQWLPHWUHV LQ RUGHU WR HDVLO UHPRYH WKH GULYLQJ ZKHHO DVVHPEO 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 lowe...

Page 224: ...WKH ULJKW DERXW 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 LVFRQQHFW WKH EUDNH FDEOH 3 IURP WKH FODPSV 4 I H G J Q N P Q L L M P200206 ...

Page 225: ...5HPRYH IURP WKH PDFKLQH WKH GULYLQJ ZKHHO DVVHPEO 9 ZLWK WKH VWHHULQJ DVVHPEO E UHPRYLQJ the hub X from the steering shaft retrieve the key Y 17 I QHFHVVDU UHPRYH WKH VFUHZV DQG WKHQ VHSDUDWH WKH GULYLQJ ZKHHO DVVHPEO 9 IURP WKH VWHHULQJ 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 disasse...

Page 226: ... previous paragraph 2 RUNEHQFK UHPRYH WKH VFUHZV RQ WKH OHIW VLGH RI WKH IURQW ZKHHO DVVHPEO 3 Remove the spacer B 4 Remove the left bracket C if necessary use a puller D 5 LWK D PDUNHU GUDZ DQ DOLJQPHQW VLJQ EHWZHHQ WKH UXEEHU ULQJ DQG WKH FDUERQ EUXVK FDS for a proper reassembly to avoid that the driving wheel turns in the wrong direction B A D E G F C P200208 ...

Page 227: ...y J take the greatest care in order not to remove displace the stator from its position 8 Remove the compensating ring K 9 3ODFH WKH DVVHPEO ZLWK WKH RXWHU VLGH 0 RI WKH ULJKW EUDFNHW OD LQJ KRUL RQWDOO RQ WKH ZRUNEHQFK 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 H J P J L N L N M K I...

Page 228: ...ion 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 t...

Page 229: ...trol 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 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ DVWHQ WKH DFFHOHUDWRU SHGDO RQ WKH VKDIW ZLWK WKH VFUHZ XQGHU WKH IROORZLQJ FRQGLWLRQ ZLWK WKH DFFHOHUDWRU SHGDO DW ...

Page 230: ...onnect the batteries SW4000 Petrol LPG 4 2Q WKH OHIW UHDU VLGH RI WKH EDWWHU HQJLQH FRPSDUWPHQW GLVHQJDJH WKH SURWHFWLRQ FDSV DQG 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 6OLJKWO OLIW WKH GULYH V VWHP HOHFWURQLF ERDUG DQG GLVFRQQHFW LWV FRQQHFWRU WKHQ UHWULHYH LW Assembly...

Page 231: ...GULYHU V VHDW PLFURVZLWFK FRQQHFWRU 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 I QHFHVVDU UHPRYH WKH VFUHZV DQG UHPRYH WKH VHDW UDLOV Assembly 9 VVHPEOH WKH FRPSRQHQWV LQ WKH UHYHUVH RUGHU RI GLVDVVHPEO DQG QRWH WKH IROORZLQJ Before tightening the screws F check that the seat rai...

Page 232: ...9DOXHV SW4000 Battery 6 3HWURO 6 3 8 WXUQ VSDFH ULJKW OHIW LQ PP RUZDUG VSHHG PL K NP K 0D LPXP UHYHUVH VSHHG PL K NP K UDGHDELOLW 20 URQW ZKHHO VSHFL F SUHVVXUH RQ WKH ÀRRU SVL 1 PP2 URQW GULYLQJ DQG VWHHULQJ ZKHHO GLDPHWHU ZLGWK LQ PP ULYH V VWHP PRWRU KS 315 rpm ...

Page 233: ......

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