Nilfisk-Advance SW900 Service Manual Download

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Electrical and Control System

Service Manual – SW900

Component Locations (SW900 B) (Continues)

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Wiring harnesses

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Main motor (M0)

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Batteries (BAT)

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Battery connector

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Main motor relay (K0)

• 5A fuse, electrical filter shaker (F1)

• 125A fuse, battery (F0)

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Reduction unit

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Filter shaker relay (K1)

P200273

Summary of Contents for SW900

Page 1: ...SW900 2013 11 Form No 1465376000 Service Manual Advance SW900 Battery 9084112010 Nilfisk SW900 Battery 9084110010 Nilfisk SW900 Petrol 9084111010 English ...

Page 2: ...nce Table SW900 P 25 Frame System 26 Frame main parts 26 Dust Control System 27 Functional Description 27 Wiring Diagram SW900 B 27 Wiring Diagram SW900 P 28 Component Locations 29 Maintenance and Adjustments 30 Panel dust filter cleaning and integrity check replacement 30 Troubleshooting 32 Removal and Installation 33 Electrical filter shaker motor amperage check 33 Electrical Filter Shaker Motor...

Page 3: ...Engine System 85 Functional Description 85 Wiring Diagram 85 Component Locations 86 Maintenance and Adjustments 87 Engine RPM Check and Adjustment 87 Troubleshooting 89 Removal and Installation 90 Engine Belt Check Adjustment Replacement 90 Petrol Engine Assembly Removal Installation 93 Specifications 97 Hopper System 98 Functional Description 98 Component Locations 99 Specifications 100 Main Broo...

Page 4: ... Reduction Unit Removal Installation 125 Right Side Broom Control Cable Removal Installation 126 Side Broom Microswitch Adjustment and Removal Installation 128 Specifications 130 Wheel System Traction 131 Functional Description 131 Component Locations 132 Maintenance and Adjustments 133 Troubleshooting 134 Removal and Installation 135 Drive system control cable disassembly assembly 135 Drive belt ...

Page 5: ...intended to help service technicians when carrying out mainte nance and repairs on the SW900 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 SW900 B Advance 9084112010 1465374000 1465375000...

Page 6: ...ts 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 serial number and model name 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 re...

Page 7: ...r 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...

Page 8: ...it mark A shown in the figure P200250 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 or the machine too much to avoid fuel spillage Do...

Page 9: ...ffoldings 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 rain and bad weather both under operation and inactiv ity condition Store...

Page 10: ...ntion to hot parts when working near the engine and the muffler For SW900 B Before using the battery charger ensure that frequency and voltage values indicated on the machine 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...

Page 11: ... 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 For SW900 B The battery connector is disconnected The machine is securely fastened to the means of transport ...

Page 12: ...General Information 12 Service Manual SW900 Machine Nomenclature SW900 B know your machine P200251 ...

Page 13: ...General Information 13 Service Manual SW900 Machine Nomenclature SW900 B Continues P200252 ...

Page 14: ...General Information 14 Service Manual SW900 Machine Nomenclature SW900 B Continues P200253 ...

Page 15: ...General Information 15 Service Manual SW900 Machine Nomenclature SW900 B Continues P200254 ...

Page 16: ...General Information 16 Service Manual SW900 Machine Nomenclature SW900 P know your machine P200255 ...

Page 17: ...General Information 17 Service Manual SW900 Machine Nomenclature SW900 P Continues P200256 ...

Page 18: ...General Information 18 Service Manual SW900 Machine Nomenclature SW900 P Continues P200257 ...

Page 19: ...General Information 19 Service Manual SW900 Machine Nomenclature SW900 P Continues P200258 ...

Page 20: ...hines Digital Volt Meter DVM Amp clamp with possibility of making DC measurements 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 Nilfi...

Page 21: ...m2 filtering capacity 5 10 µm Power 12V batteries Power 2 1 kW 3 600 rpm Engine model Honda GX 100 Fuel tank capacity 0 77 liters Main motor power drive main broom vacuum system 0 9 hp 680 W Dynamotor power drive main broom vacuum system 0 26 hp 198 W Main broom speed 420 rpm Side broom motor power 0 05 hp 40 W speed 100 rpm Drive forward speed 2 8 mi h 4 5 km h Maximum gradient when working 2 Fil...

Page 22: ...level at the operator s arms ISO 5349 1 98 in s2 2 5 m s2 157 in s2 4 m s2 Machines have been tested under the following conditions Battery maximum size Brooms of maximum size Full hopper 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 Under normal working conditions o...

Page 23: ...General Information 23 Service Manual SW900 Dimensions P200259 ...

Page 24: ... maintenance procedures see the following paragraphs Scheduled Maintenance Table SW900 B Procedure Upon delivery Every 10 hours Every 50 hours Every 200 hours Every 400 hours Battery charging 1 Battery WET fluid level check Battery charger cable check Dust filter cleaning and integrity check 2 Side and main broom height check and adjustment Skirt height and operation check Dust filter holder gaske...

Page 25: ...g 5 Fuel tank and filter cleaning 4 5 Engine speed check Dust filter holder gasket check Engine air filter replacement 3 5 Spark plug replacement 2 5 Valve clearance check adjustment 4 5 Hopper gasket integrity check Hopper position microswitch operation check Drive belt replacement engine drive system main broom Dynamotor carbon brush check and replacement Engine combustion chamber cleaning 4 5 F...

Page 26: ...Frame main parts Technopolymer main frame Front element anchoring rear wheels Rear metal frame Engine battery and drive system holder Center element supporting filter and main broom Front element supporting hopper steering wheel and side brooms P200260 ...

Page 27: ...onsists of a fan installed on the main motor dynamotor which is powered by the re lay K0 see Electrical and Control System chapter VERSION WITH ELECTRICAL FILTER SHAKER The electric filter shaker system consists of a motor M1 which is powered by the relay K1 and protected by the fuse F1 see Electrical and Control System chapter VERSION WITH MANUAL FILTER SHAKER By operating on the lever on the rig...

Page 28: ...Dust Control System 28 Service Manual SW900 Wiring Diagram SW900 B with manual filtershaker P200261 Wiring Diagram SW900 P P200262 ...

Page 29: ...Dust Control System 29 Service Manual SW900 Component Locations Main motor SW900 B Dynamotor SW900 P Filter and pre filter panel Gaskets Filter shaker M1 Fuse F1 5A Relay K1 P200264 ...

Page 30: ... safety glasses dust mask gloves etc and clean the filter in a well ventilated area Take care not to pierce the filter Note Besides the standard polyester filter paper filters are also available 1 Drive the machine on a level floor and ensure that it cannot move 2 Turn the ignition key to 0 3 Remove the hopper by using its transport handle and wheels 4 If equipped remove the pre filter A after rel...

Page 31: ...better clean ing 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 Paper filter optional Do not use water or detergents to clean it the filter can be dam aged 9 Check the filter body for tears 10 Clean ...

Page 32: ...oes not work The hopper is full Empty the hopper The main motor circuit breaker FA is open Wait for the main motor to cool down then reset the fuse by pressing the relevant push button The fuse F2 is open Replace the fuse The relay K1 is broken Replace Dust debris vacuuming is insufficient The switch SW1 is not efficient Replace The filter shaker is broken Repair replace The filter is clogged Clea...

Page 33: ...attery engine hood 5 Apply the amp clamps A on one cable B of the filter shaker motor connection wiring harness 6 Carefully operate and keep operated the hopper position microswitch C to simulate the presence of the hopper 7 For SW900 B Turn the ignition key to I For SW900 P Turn the ignition key to I and start the petrol engine 8 Carefully activate the electrical filter shaker switch D and check ...

Page 34: ...tion of all its components Before removing the filter shaker motor E check that the filter shaker frame F can slide on the spacer bushes of the springs G overcoming the resistance of the springs and that it is not locked If the above mentioned procedures do not produce the correct readings for the electrical filter shaker motor amperage the motor must be replaced see the procedure in the relevant ...

Page 35: ...ignition key to 0 3 Remove the hopper by using its transport handle and wheels 4 Disengage the front fastener and open the battery engine hood 5 For SW900 B Remove the batteries and their container see the procedure in the relevant paragraph 6 Disconnect the wet by pass hoses A from the deflector B 7 Remove all the mounting screws C of the deflector B 8 Move aside the conveyor B P200269 ...

Page 36: ... the four screws P 12 For disassembly of the motor E with its of the frame G electrical filter shaker remove the screws H and recover the springs I the washers J and the spacer bushes K Check the integrity of the disassembled parts Assembly 13 Assemble the components in the reverse order of disassembly and note the following When reinstalling of the spacer bushes K make sure that the same should a...

Page 37: ...ilfisk SW900 P Filter cleaning system Electrical filter shaker manual on Advance version area 20 5 ft2 1 9 m2 filtering capacity 5 10 µm Filter shaker motor 12 W Paper filter filtering capacity 99 0 8 µm Air flow 11301 ft3 h 320 m3 h Broom compartment vacuum new filter 0 13 inH2 O 3 6 mmH2 O ...

Page 38: ...itch K0 and activates the relay K1 The electromagnetic switch K0 directly drives the main motor M0 and the side broom motors M2 and M3 while the relay K1 if equipped turns on the filter shaker motor M1 On the circuit of the side broom motors M2 and M3 there are microswitches SW2 and SW3 respectively which deactivate the relevant motors when the brooms are lifted from the ground by means of the man...

Page 39: ...ed or if the upper hood is open On the versions equipped with electrical filter shaker the dynamotor G powers also the filter shaker switch SW1 which when pressed activates the relay K1 The relay K1 turns on the filter shaker motor M1 On the circuit of the side broom motors M2 and M3 there are microswitches SW2 and SW3 respectively which deactivate the relevant motors when the brooms are lifted fr...

Page 40: ...A FILTER SHAKER MOTOR M1 5A FILTER SHAKER MOTOR M1 F2 30A BATTERY CHARGER CH FA 70A MAIN MOTOR M0 20A DYNAMOTOR M0 FB 5A RIGHT SIDE BROOM MOTOR M2 5A RIGHT SIDE BROOM MOTOR M2 FC 5A LEFT SIDE BROOM MOTOR M3 5A LEFT SIDE BROOM MOTOR M3 Relays Electromagnetic Switches Diodes Acronym SW900 B SW900 P Activated function Activated function K0 MAIN MOTOR M0 K1 FILTER SHAKER M1 FILTER SHAKER M1 ...

Page 41: ... RIGHT SIDE BROOM MOTOR M2 LEFT SIDE BROOM MOTOR M3 HOPPER MICROSWITCH SW0 FILTER SHAKER SWITCH SW1 RIGHT SIDE BROOM MICROSWITCH SW2 LEFT SIDE BROOM MICROSWITCH SW3 LDG LDY LDR COM M0 M2 M3 M1 P200306 Wiring Diagram SW900 B with manual filtershaker LDG LDY LDR COM M0 M2 M3 BATTERY CHARGER CH 12 V BATTERIES BAT LED ELECTRONIC BOARD EB1 BATTERY CHARGER FUSE 30 A F2 MAIN MOTOR CIRCUIT BREAKER 70 A FA...

Page 42: ...HT SIDE BROOM CIRCUIT BREAKER 5 A FB LEFT SIDE BROOM CIRCUIT BREAKER 5 A FC HOUR COUNTER HM RIGHT SIDE BROOM MICROSWITCH SW2 LEFT SIDE BROOM MICROSWITCH SW3 IGNITION KEY KEY LEFT SIDE BROOM MOTOR M3 RIGHT SIDE BROOM MOTOR M2 DYNAMOTOR G FRAME FR M3 M2 G FILTER SHAKER FUSE 5 A F1 FILTER SHAKER MOTOR M1 FILTER SHAKER SWITCH SW1 M1 FILTER SHAKER RELAY K1 P200307 ...

Page 43: ...Electrical and Control System 43 Service Manual SW900 Component Locations SW900 B Dashboard Ignition key KEY Filter shaker SW1 Hour counter HM LED electronic board EB1 P200308 ...

Page 44: ...ce Manual SW900 Component Locations SW900 B Continues Wiring harnesses Main motor M0 Batteries BAT Battery connector Main motor relay K0 5A fuse electrical filter shaker F1 125A fuse battery F0 Reduction unit Filter shaker relay K1 P200273 ...

Page 45: ...W900 Component Locations SW900 B Continues Battery charger CH Hopper position microswitch SW0 30A fuse battery charge F2 70A circuit breaker main motor FA 5A circuit breaker right side broom motor FB 5A circuit breaker left side broom motor FC P200309 ...

Page 46: ...Electrical and Control System 46 Service Manual SW900 Component Locations SW900 P Dashboard Ignition key KEY Filter shaker SW1 Hour counter HM P200310 ...

Page 47: ...and Control System 47 Service Manual SW900 Component Locations SW900 P Continues Wiring harnesses Dynamotor G Filter shaker relay K1 Electrical filter shaker F1 fuse 5A Dynamotor FA fuse 20A Reduction unit P200274 ...

Page 48: ...l and Control System 48 Service Manual SW900 Component Locations SW900 P Continues Hopper position microswitch SW0 Right side broom motor FB circuit breaker 5A Left side broom motor FC circuit breaker 5A P200311 ...

Page 49: ... the machine is equipped with lead WET batteries battery charging produces highly explosive hydrogen gas Charge the batteries in well ventilated areas and away from naked flames Do not smoke while charging the batteries While charging the batteries always keep the hood open Warning Pay careful attention when charging lead batteries WET as there may be battery fluid leakages The battery fluid is co...

Page 50: ...harger values shown on the machine serial number plate Note When the electronic battery charger is connected to the electrical mains all machine functions are automatically disabled 4 When the green LED E turns on the batteries are charged For further information about the battery charger operation see the Battery Charger Manual 5 Disconnect the electronic battery charger electrical cable D from t...

Page 51: ...eset any deactivated fuse when the component that caused deactivation has fully cooled down Various Fuse Check Replacement 5 Remove the hopper by using its transport handle and wheels 6 Disengage the front fastener and open the battery compartment hood 7 Disconnect the battery connector 8 Remove the rear grid after removing the upper mounting screw and disengaging the fasteners 9 Disengage and ope...

Page 52: ...125A fuse F0 battery When reinstalling the fuse F engage its flange G on the electrical cable terminals H as shown in the figure Reassembly 12 Install the rear grid by engaging the fasteners and then tighten the upper mounting screw 13 Connect the battery connector 14 Close the battery compartment hood and engage the front fastener 15 Install the hopper by using its transport handle and wheels P20...

Page 53: ...otor 4 Reset any deactivated fuse when the component that caused deactivation has fully cooled down Lamellar Fuse Check Replacement 5 Remove the hopper by using its transport handle and wheels 6 Disengage the front fastener and open the engine compartment hood 7 On the right side of the engine C check replace the fuses D 20A fuse F0 main E 5A fuse F1 electrical filter shaker Reassembly 8 Close the...

Page 54: ...n of the microswitch The upper hood is open Close it properly Check the operation of the microswitch The circuit breaker FA is open Press the push button on the fuse if the trouble persists remove the overload cause The right left broom motor does not run The lever is not activated correctly Use the lever up to the end of stroke Check the operation of the microswitch The circuit breaker FB or FC i...

Page 55: ...charger plug Handle the batteries with great care Install the battery terminal protection caps supplied with the machine 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 The machine requir...

Page 56: ...om the battery terminals 7 Disconnect the battery terminals 8 Carefully remove the batteries B Battery installation 1 Install on the machine the type of batteries which is compatible with the setting of the machine for checking the setting of the machine or to change it refer to the procedure described below 2 Route and install the battery cables then carefully tighten the nut on each battery term...

Page 57: ...ion check the number and color of the LED flashings B then compare them with the indications in the following table to determine the battery setting of the machine Type of battery set on the machine Flashes EXIDE Two flashes of the yellow LED OPTIMA Two flashes of the green and yellow LEDs together DISCOVER Two flashes of the red and green LEDs together GEL AGM generic Two flashes of the green LED...

Page 58: ...itch EXIDE OFF OFF OFF OPTIMA OFF ON OFF DISCOVER ON OFF OFF GEL AGM generic ON ON OFF WET all makes Any Any ON Set the switch H as shown below For batteries having capacity of 150Ah or higher discharge in 5 hours leave the default setting to OFF nominal charge current 25A For batteries having capacity lower than 150Ah discharge in 5 hours set H switch to ON nominal charge current 15A 13 Repeat st...

Page 59: ... 6 Remove the screws A and the right side panel B from the machine 7 Turn the tensioner C in the direction shown by the arrow and disengage the belt D from the pulley E 8 Turn the tensioner F in the direction shown by the arrow and disengage the belt G from the pulley H 9 Apply amp clamps on a cable I of the main motor J 10 Carefully operate and keep operated the hopper position microswitch K to s...

Page 60: ... its components If the above mentioned procedures do not lead to a correct amperage the main motor must be replaced see the procedure in the relevant paragraph Reassembly 15 Release the hopper position microswitch K from the forced operation and check that the microswitch operates properly 16 Turn the tensioner F in the direction shown by the arrow and engage the belt G to the pulley H and to the ...

Page 61: ...esence of the hopper 5 Check that the main and side brooms s are lifted 6 Turn the ignition key to I and start the petrol engine as shown in the User Manual wait at least 5 minutes that the engine reaches the target speed 7 Disengage the front fastener and open the engine compartment hood 8 Move aside the guards A of the terminals B and C of the dynamotor D 9 Apply the detectors E and F of the tes...

Page 62: ... correctly closed Check the dynamotor carbon brushes see the procedure in the relevant paragraph If necessary disassemble the dynamotor see the procedure in the relevant para graph and check the condition of all its components If the above mentioned procedures do not lead to a correct voltage the dynamotor must be replaced see the procedure in the relevant paragraph Reassembly 10 Close the engine ...

Page 63: ...the fastener C and remove the protection band D of the carbon brushes 9 Remove the fastening screws E of the electrical connections of the four carbon brushes F 10 Remove the four carbon brushes F from their housings by disengaging them from the retaining springs G 11 Check the two carbon brushes F for wear Replace the carbon brushes when the contact with the motor armature is insufficient the car...

Page 64: ...brushes 7 Remove the fastening screws E of the electrical connections of the four carbon brushes F 8 Remove the four carbon brushes F from their housings by disengaging them from the retaining springs G 9 Check the two carbon brushes F for wear Replace the carbon brushes when the contact with the dynamotor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not...

Page 65: ...d their container see the procedure in the relevant paragraph 6 Remove the screws A and the right side panel B from the machine then remove also the left side panel 7 Remove the rear grid C after removing the upper mounting screw D and disengaging the fasteners 8 Turn the tensioner E in the direction shown by the arrow and disengage the belt F from the pulley G 9 Turn the tensioner H in the direct...

Page 66: ... Disengage the protection caps N and disconnect the electrical connections O of the main motor 12 Loosen the clamp P and disconnect the wet by pass hose Q 13 Remove the screws R with nut S 14 On the inner side of the main motor T remove the screws U 15 Carefully remove the main motor assembly with the reduction unit V Main Motor or Fan Removal Installation SW900 B Continues ...

Page 67: ...inues 16 At the workbench remove the screws with the nut W 17 Remove the four screws X and disconnect the motor Y from the reduction unit Z by disengaging the shaft with key AH if necessary use a plastic mallet 18 If necessary remove the fan AA as shown below 19 Remove the screw AB and the dowel AC P200319 ...

Page 68: ...f the shaft and on the groove AE remove the fan AA from the shaft 21 If necessary remove the four screws AG and remove the flange AF Assembly 22 Assemble the components in the reverse order of disassembly and note the following Reinstall the flange AF with the side AH turned to the opposite side of the motor elec trical connection terminals AI P200320 ...

Page 69: ...d 5 Remove the screws A and the right side panel B from the machine then remove also the left side panel 6 Disconnect the engine belt from the reduction unit pulley refer to the procedure for engine belt replacement in the relevant paragraph 7 Turn the tensioner E in the direction shown by the arrow and disengage the belt F from the pulley G 8 Turn the tensioner H in the direction shown by the arr...

Page 70: ... M 10 Disengage the protection caps N and disconnect the electrical connections O of the dynamotor 11 Loosen the clamp P and disconnect the wet by pass hose Q 12 Remove the screws R with nut S 13 On the inner side of the dynamotor T remove the screws U 14 Carefully remove the dynamotor assembly with the reduction unit V Dynamotor Removal Installation SW900 P Continues ...

Page 71: ...s 15 At the workbench remove the screws with the nut W 16 Remove the four screws X and disconnect the motor Y from the reduction unit Z by disengaging the shaft with key AH if necessary use a plastic mallet 17 If necessary remove the fan AA as shown below 18 Remove the screw AB and the dowel AC P200319 ...

Page 72: ... shaft and on the groove AE remove the fan AA from the shaft 20 If necessary remove the four screws AG and remove the flange AF Assembly 21 Assemble the components in the reverse order of disassembly and note the following Reinstall the flange AF with the side AH turned to the opposite side of the dynamotor electrical connection terminals AI P200320 ...

Page 73: ...it from the reduction unit see the procedure in the relevant paragraph 2 Remove the screw A of the reduction unit B 3 Remove the four screws C 4 Remove the reduction unit B by pushing it in the direction shown by the arrow D and by disengaging it from the shaft with key E If necessary use a plastic mallet Assembly 5 Assemble the reduction unit in the reverse order of disassembly P200322 ...

Page 74: ...en the battery engine compartment hood 5 Remove the screws A and the right side panel B from the machine 6 Remove the rear grid C after removing the upper mounting screw D and disengaging the fasteners 7 Turn the tensioner E in the direction shown by the arrow and disengage the belt F from the pulley G 8 Turn the tensioner H in the direction shown by the arrow and disengage the belt I from the pul...

Page 75: ...ontinues 9 Operating in the back side of the reduction unit cut the clamp K fastening the wiring harness L 10 Remove the two screws M and remove the gear case N 11 Remove the four screws with nut O and the pulley assembly with gear P 12 At the workbench remove the screw Q and the dowel R then remove the pulley S ...

Page 76: ... Small Gear Removal Installation Continues 13 Unscrew the two dowels T of the bearing 14 Remove the assembly U from the shaft X 15 Remove the spacer V 16 Remove the gear W from the shaft with key X Assembly 17 Assemble the gear in the reverse order of disassembly P200324 ...

Page 77: ...d open the battery engine compartment hood 5 Remove the screws A and the right side panel B from the machine 6 Remove the rear grid C after removing the upper mounting screw D and disengaging the fasteners 7 Turn the tensioner E in the direction shown by the arrow and disengage the belt F from the pulley G 8 Turn the tensioner H in the direction shown by the arrow and disengage the belt I from the...

Page 78: ...n the back side of the reduction unit cut the clamp K fastening the wiring harness L 10 Remove the two screws M and remove the gear case N 11 Remove the two screws with nut O and then remove the half flange P P200325 Drive Shaft Big Gear Removal Installation Continues ...

Page 79: ...readed hole S of the reduction unit 14 With a plastic mallet slightly tap on the screw R in the direction shown by of the arrow T until the gear assembly with shaft U comes out 15 Remove the spacer V and the gear W from the shaft X with key Assembly 16 Assemble the gear in the reverse order of disassembly Drive Shaft Big Gear Removal Installation Continues ...

Page 80: ... A after removing the upper mounting screw B and disengaging the fasteners 3 Disconnect the electrical connector C from the battery charger D 4 Disconnect the electrical terminal E from the fuse 5 Cut the fastening clamps F of the battery charger cables G 6 Disconnect the terminal H of the cable G from the battery terminal P200327 Battery Charger Removal Installation SW900 B ...

Page 81: ... M and then by lifting the front part in the direction shown by the arrow N Assembly 11 Assemble the battery charger in the reverse order of disassembly and note the following When installing a new battery charger this must be set according to the type of batter ies which are going to be installed on the machine see the procedure in the relevant paragraph Set the battery charger before installing ...

Page 82: ...gage the front fastener and slightly lift the battery engine compartment hood A then check that on the left side there is the tab B which activates the hopper position switch if necessary replace the battery engine compartment hood 6 Check that the inner vane C which activates the hopper position switch is integral and swings freely in the direction shown by the arrow E and that the return spring ...

Page 83: ...locknut L 11 If necessary loosen the screws M and adjust the position of the switch I by moving it in the direction shown by the arrow N when the adjustment is completed tighten the screws M 12 If necessary remove the screws M and disconnect the electrical connections O then remove and replace the switch I then adjust the hopper position switch I see the previous steps Hopper Position Switch Opera...

Page 84: ...ower 12V batteries Main motor power drive main broom vacuum system 0 9 hp 680 W Dynamotor power drive main broom vacuum system 0 26 hp 198 W Total absorbed power 1 02 hp 0 76 kW Working autonomy 3 h 1 5 h Dimensions length x width x height battery compartment 12 9 x 9 x 15 in 327 x 230 x 380 mm IP protection class X3 ...

Page 85: ...ternal combustion engine and dynamotor which are both connected by a belt The engine is a single cylinder air cooled petrol type The engine start up is made by means of a self wind ing system The engine speed is fixed to 2 950 rpm to grant a constant current to the electrical system The fuel tank is applied to the engine The tank is equipped with a valve with integrated filter Wiring Diagram P2003...

Page 86: ...e System 86 Service Manual SW900 Component Locations Petrol engine Engine switch Engine oil filler plug Engine oil drain plug Engine belt Engine oil level outer check plug Engine oil level inner check plug P200332 ...

Page 87: ...n the engine pulley C an adhesive indicator D for counting the engine speed 5 Turn the ignition key to I and start the petrol engine as shown in the User Manual wait 5 10 minutes that the engine reaches the target speed 6 Point a revolution counter on the adhesive indicator D of the engine pulley C then detect the engine speed which must be 3 000 50 rpm If necessary adjust the engine speed as show...

Page 88: ...ont fastener and open the engine compartment hood 12 Carefully loosen the nut F and move the lever G as necessary to adjust engine rpm and refer to the plate H for the direction of movement After adjusting tighten the nut F Reassembly 13 Turn off the petrol engine as shown in the User Manual 14 Turn the ignition key to 0 15 Close the engine compartment hood and engage the front fastener 16 Release...

Page 89: ...performing fuel treatment or without draining it the machine has been re fuel with poor quality gasoline Drain the fuel tank and the carburetor Refuel with fresh gasoline The fuel tank is empty Refuel The spark plug is damaged dirty or the dis tance between the electrodes is wrong Correct the distance between the electrodes or replace the spark plug The spark plug is wetted with fuel flooded engin...

Page 90: ...f necessary replace the belt 5 Check the proper tension of the belt which can occur when pressing the belt in middle area between the two pulleys with a force D of approximately 1 Kg the belt is moving of an arrow E of 15 20 mm If necessary adjust the belt tension as shown below Loosen the four mounting screws F of the engine assembly H to the holder G then move the engine assembly as necessary wh...

Page 91: ...lley J then check for the proper align ment If necessary adjust the alignment as shown below Loosen the four nuts L fastening the engine holder G to the vibration damp ers then adjust the alignment of the two pulleys by sliding the plate G with engine assembly when the adjustment is completed tighten the nuts L 7 The pad M must slightly contact the holder G then if necessary adjust its position by...

Page 92: ... screws F fastening the engine assembly H to the holder G then move the engine assembly toward the dynamotor as possible Disengage the engine belt C from the engine pulley I using a screwdriver as a lever and by simultaneously turning the engine pulley I by slightly pulling the engine pull start cord Retrieve the engine belt C by disengaging it from the reduction unit pulley J 5 Install the new be...

Page 93: ...5 Disconnect the engine electrical connections A and B 6 Open the fastening clamp C and disconnect the engine ground D 7 Remove the rear grid E after removing the upper mounting screw F and disengaging the fasteners 8 Remove the screws G and the bulkhead H 9 Disengage the engine belt I from the engine pulley J using a screwdriver as a lever and by simultaneously turning the engine pulley J by slig...

Page 94: ...Assembly Removal Installation Continues 11 Carefully lift and remove the engine assembly M engine weight 10 9 Kg approx If necessary at the workbench separate the following parts from the engine N Guard P Oil drain hose Q Engine pulley R Engine holder S P200291 ...

Page 95: ...agraph When installing a new engine Check if there is oil in the engine Check for proper alignment of the engine exhaust pipe W to the machine exhaust end pipe X if necessary loosen the screws Y and adjust Then tighten the screws Y Remove the three screws S and turn the case T for 120 to turn the outlet hole U of the engine pull start cord V in the position shown in the figure Tighten the screws S...

Page 96: ...etrol Engine Assembly Removal Installation Continues Connect the engine electrical cables A and B as shown in the figure Check the engine oil level as shown in the User Manual Check the engine rpm see the procedure in the relevant paragraph P200335 ...

Page 97: ... Cooling Air Fuel Gasoline Cycle Cycle 8 Maximum engine speed max power 3 600 rpm 2 1 kW Minimum engine speed min power 2 000 rpm 1 CV Fuel consumption at 2 500 rpm 390 g hour Fuel consumption at 3 600 rpm Fuel consumption at 3 600 rpm Oil pan capacity 1 514 gal 0 4 L Engine oil type SAE 10W30 Emission certifications VCA Cert No e11 97 68SA 2002 88 0305 01 Fuel tank capacity 0 77 liters Engine oil...

Page 98: ...an be dragged on the wheels provided for the transport to reach the discharge area To lift the hopper in addition to the transport handle there is a handle x x x x x to grab it properly The hopper is provided with two skirts a front skirt for debris collection and an intermediate one to pro tect the filter from the material launched from the main broom and to help the filter powders to fall into t...

Page 99: ...Hopper System 99 Service Manual SW900 Component Locations Hopper Dust filter protection skirt Front skirt P200336 ...

Page 100: ...ystem 100 Service Manual SW900 Specifications Model Advance Nilfisk SW900 B Nilfisk SW900 P Hopper Real capacity 0 88 ft3 25 Liters Theoretic capacity 2 8 ft3 79 Liters Maximum transportable weight 66 lb 30 kg ...

Page 101: ...he broom is supported by a idle hub fixed to a plate stuck to the broom holder The knob in the rear side of the machine determines the broom lowering lifting and therefore the relevant pressure on the floor The door on the left side of the machine can be opened with the foldable lever so that the idle hub mounting plate can be reached By loosening the two knobs fastening the mounting plate to the ...

Page 102: ...omponent Locations Main broom Main broom belt Pulley with hexagonal drive hub Hexagonal drive hub Main broom height adjusting knob Front skirt Rear skirt Right side skirt Right side recovery skirt Left side skirt Left side recovery skirt P200295 ...

Page 103: ...Turn the knob B taking into account what follows see also the descriptive plate C to increase the print width turn the knob counter clockwise to decrease the print width turn the knob clockwise Note The adjustment of the broom print on the floor must be performed periodically also according to the consumption of the bristles 3 Perform step 1 again to check the proper adjustment of the main broom d...

Page 104: ... Check 5 Unscrew the nuts A and remove the rear side cover B 6 Check the side skirt C and the recovery skirt D for integrity Replace the skirts when they have cuts E larger than 20 mm or cracks tears F larger than 10 mm see the procedure in the relevant paragraph 7 Check that the height G of the side skirt C and recovery skirt D is 0 3 mm If necessary for the side skirt C loosen the nuts H and the...

Page 105: ...grity Replace the skirts when they have cuts F larger than 20 mm or cracks tears G larger than 10 mm see the procedure in the relevant paragraph 10 Check that the height H of the side skirt D and recovery skirt E is 0 3 mm If necessary For the side skirt D loosen the nuts I and the screws J then adjust the position of side skirt D Then tighten the nuts I and the screws J For the recovery skirt E l...

Page 106: ...ly rub the floor without being detached from it 15 If necessary adjust the rear skirt height according to the following procedure Remove the hopper by using its transport handle and wheels Loosen the screws K and adjust the height of the rear skirt H by using the slots of the mounting holes After adjusting tighten the screws K If it is not possible to adjust the rear skirt properly replace it see ...

Page 107: ...lter is clogged Clean the dust filter by using the filter shaker or by disassembling it The hopper is full Empty the hopper The skirts are not properly adjusted or are broken Adjust replace the skirts The brooms are not properly adjusted Adjust the broom height The main broom belt is misadjusted or worn Adjust or replace the main broom belt ...

Page 108: ...e gloves when replacing the main broom because there can be sharp debris between the bristles Disassembly 1 Drive the machine on a level floor and ensure that it cannot move 2 Turn the ignition key to 0 3 Remove the hopper by using its transport handle and wheels 4 Fully turn the main broom height adjusting knob A clockwise by lifting it 5 Lift the tab B and turn the knob C counter clockwise until...

Page 109: ... slightly lift the front side of the machine to remove the main broom easily Assembly 8 Check that the main broom hexagonal drive hub H is free from dirt or foreign materials ropes rags etc accidentally rolled up 9 Install the main broom G The bristles I must be bent in the direction shown in the figure 10 Install the main broom G by inserting it in the front side of the machine by engaging its me...

Page 110: ...Main Broom Removal Installation Continues 12 Lift and close the left door D and fasten it with the knob C lower the tab B in its housing 13 Reinstall the hopper 14 Adjust the main broom height see the procedure in the relevant paragraph P200302 ...

Page 111: ...loor and ensure that it cannot move 2 Turn the ignition key to 0 3 Remove the hopper by using its transport handle and wheels 4 Disengage the front fastener and open the battery engine compartment hood 5 Remove the screws A and the right side panel B from the machine 6 Remove the nuts C and the right cover D P200303 ...

Page 112: ...eely and are free from dirt and foreign materials ropes clothes etc accidentally rolled up on their rotation shafts Replacement 9 Disengage the flexible tensioner F from the belt E then release the belt from the pulleys G and H 10 Remove the fastening screws I of the plate J 11 Move the plate J with the pulley K by disengaging the hexagonal drive hub L from the socket M of the main broom 12 Retrie...

Page 113: ...y 1 Remove the main broom belt see the procedure in the previous paragraph 2 At the workbench remove the snap ring A and remove the bearing D and the hexagonal drive hub with pulley B from the mounting plate C Assembly 3 Assemble the hexagonal drive hub with pulley in the reverse order of disassembly P200305 ...

Page 114: ...to 0 3 Remove the hopper by using its transport handle and wheels 4 Unscrew the nuts A and remove the rear side cover B 5 Remove the screws C and release the flange D 6 Remove the nuts E and loosen the inner screw F 7 Remove the right side skirt G 8 Install the right side skirt by performing the steps 3 to 7 in the reverse order 9 Check the right side skirt height see the procedure in the relevant...

Page 115: ...erforming the steps 3 to 5 in the reverse order 7 Check the left side skirt height see the procedure in the relevant paragraph Right and Left Side Recovery Skirt Disassembly Assembly 1 Drive the machine on a level ground that is suitable for checking the skirt height Make sure that the machine cannot move independently 2 Turn the ignition key to 0 3 Remove the hopper by using its transport handle ...

Page 116: ...5 in the reverse order 7 Check the front skirt height see the procedure in the relevant paragraph Rear Skirt Disassembly Assembly 1 Remove the main broom see the procedure in the relevant paragraph 2 Fully turn the main broom height adjusting knob C counter clockwise by lifting it 3 In the main broom compartment remove the screws D then remove the metal strap E and the rear skirt F 4 Install the r...

Page 117: ...Main Broom System 117 Service Manual SW900 Specifications Model Advance Nilfisk SW900 B Nilfisk SW900 P Main broom size length x diameter 23 6 x 10 4 in 600 x 265 mm Main broom speed 420 rpm ...

Page 118: ...ivate the relevant motors when the brooms are lifted from the ground by means of the manual levers on the handlebar The side broom motors M2 and M3 are protected by 5A circuit breakers FB and FC respectively Petrol Version The dynamotor G provides the current necessary for the activation of the side broom motors M2 and M3 When the engine is turned on the current generat ed by the dynamotor G direc...

Page 119: ...Side Broom System 119 Service Manual SW900 Wiring Diagram SW900 B P200343 Wiring Diagram SW900 P P200344 ...

Page 120: ...room motor M3 Right side broom Left side broom Right side broom microswitch SW2 Left side broom microswitch SW3 Right side broom lifting lowering and height adjusting lever Left side broom lifting lowering and height ad justing lever Right side broom control cable Left side broom control cable P200345 ...

Page 121: ... off 5 Check the side broom print The print is correct when the bristles touch the floor along a circle arc A as shown in the figure 6 If necessary adjust the height of the side broom by using the mechanical end of stroke B after loosening the locknut C when the adjustment is completed tighten the locknut C 7 When the broom is too worn to be adjusted replace it see the procedure in the relevant pa...

Page 122: ...ot operate The circuit breaker FB or FC optional is open Wait for the side broom motor to cool down then reset the fuse by pressing the relevant push button The main fuse FA is open Replace the main fuse The side broom microswitch is faulty or misadjusted Replace the relevant side broom microswitch or adjust it ...

Page 123: ...n a level floor and ensure that it cannot move 2 Lift the side broom until the end of stroke by using the lever 3 Turn the ignition key to 0 4 Loosen the knob A inside the side broom then remove the side broom B by disengaging it from the three positioning pins C Assembly 5 To install the side broom easily use its lifting lever by turning it to fully lowered position 6 Install the side broom in it...

Page 124: ...For SW900 P Turn the ignition key to I and start the petrol engine as shown in the User Manual wait a few minutes that the engine reaches the target speed 6 With the lever lower and activate the side broom to be checked and then check that the motor amperage is between 1 and 3A at 24V 7 Lift the side broom and stop its rotation 8 Turn the ignition key to 0 9 Remove the amp clamp 10 If the amperage...

Page 125: ...broom see the procedure in the relevant paragraph 2 Remove the screws A and the nut B then remove the side broom reduction unit guard C 3 Unscrew the dowel D and remove the broom hub E 4 Remove the mounting screws F of the side broom reduction unit G 5 Cut the clamp H 6 Disconnect the electrical connector I and remove the reduction unit J of the side broom Assembly 7 Assemble the reduction unit in...

Page 126: ... Remove the hopper by using its transport handle and wheels 4 Disengage the front fastener and open the battery engine compartment hood 5 Remove the screws A and the side panel B 6 Right side Remove the nuts C and the right cover D Left side Lift the tab E and turn the knob F counter clockwise until it is disengaged then open the left door G 7 Remove the screws H and the nut I then remove the side...

Page 127: ...the nut L 10 Disengage the cable M from the slot N 11 Cut the clamps P retaining the cable O 12 Unscrew the nut Q and remove the lever R with the cable Assembly 13 Assemble the cable in the reverse order of disassembly and note the following After installation perform the adjustment of the cable M see the procedure for adjusting the side broom microswitch P200351 ...

Page 128: ...ction unit is the same Adjustment 1 Drive the machine on a level floor and ensure that it cannot move 2 Turn the ignition key to 0 3 Remove the hopper by using its transport handle and wheels 4 Disengage the front fastener and open the battery engine compartment hood 5 For SW900 B Disconnect the battery connector 6 Remove the screws A and the nut B then remove the side broom motor guard C P200352 ...

Page 129: ...cated by the previous step loosen the screws with the nut H and lower the microswitch I until its terminal J on the vane L is activated the terminal J must also slightly bend the vane L downwards In this condition tighten the screws with the nut H of the microswitch Disassembly 9 If necessary disconnect the electrical connections K remove the screws with the nut H and then remove the microswitch I...

Page 130: ...SW900 P Cleaning width with one side broom 32 5 in 825 mm with two side brooms 41 3 in 1 050 mm Side broom diameter 12 4 in 315 mm Theoretical working capacity with one side broom 35 520 ft2 h 3 300 m2 h with two side brooms 45 208 ft2 h 4 200 m2 h Side broom motor power 0 05 hp 40 W speed 100 rpm ...

Page 131: ...center part of the handle activates an idler pulley which tightens the belt which trans mits the motion to the right rear wheel on which the driven pulley is installed The rear wheels are equipped with a particular sys tem which allows for the rotation only in one direc tion There is therefore a right wheel marked with a colored sticker and a left wheel The wheels are axially fastened on the prope...

Page 132: ...Wheel System Traction 132 Service Manual SW900 Component Locations Drive control lever Drive system control flexible cable Drive belt Pulley Drive wheels P200354 ...

Page 133: ... belt 3 Gradually bring the drive control lever A to half stroke In this condition the machine should start to move but it must be still easy to hold it in place by pulling the handlebar B there must be no noise whistling etc caused by the drive belt 4 Carefully bring the drive control lever A until the end of the stroke in this condition the machine must move at maximum speed 5 If necessary adjus...

Page 134: ...le Possible causes Remedy When pulling the drive control lever the machine does not move or it moves slowly The drive control cable is misadjusted or broken Adjust or replace the drive control cable The drive belt is misadjusted or worn Adjust or replace the drive belt ...

Page 135: ...inal D from the tensioner E 5 Loosen the nut F on the handlebar 6 Disconnect the cable G from the slot H on the holder 7 Remove the terminal I of the cable G from the housing of the drive control lever J 8 Retrieve the drive system control cable G Assembly 9 Assemble the drive system control cable in the reverse order of disassembly 10 Adjust the drive system control cable see the procedure in the...

Page 136: ...essary replace it If necessary replace the belt 7 Check that the flexible tensioner D is working and that it operates correctly on the drive belt C Check that the rotation pulleys of the belt C rotate freely and are free from dirt and foreign materials ropes clothes etc accidentally rolled up on their rotation shafts Replacement 8 Move the flexible tensioner D away from the belt C then release the...

Page 137: ... h Maximum gradient when working 2 Gradeability at full load and during transfer 18 Front wheels quantity diameter width N 1 Ø3 9 x 1 2 in N 1 Ø100 x 30 mm Rear wheels quantity diameter width N 2 Ø9 8 x 2 1 in N 2 Ø250 x 54 mm Minimum hallway width 40 9 in 1 040 mm Front rear wheelbase 33 6 in 853 mm Track centres of rear wheels 28 6 in 727 mm ...

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Nilfisk-Advance SW900, Service Manual

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