Page 1: Service Manual
SW8000 Service Manual Nilfisk Model Numbers: Advance Model Numbers: 56107501 65” Gasoline 56107512 165 cm LPG 56107503 65” LPG 56107513 165 cm Diesel 56107505 65” Diesel 56107514 165 cm LPG w/ cab 56107507 65” Gasoline w/ cab 56107515 165 cm Diesel w/ cab 56107509 65”...
Page 2: Table Of Contents
Service Manual – SW8000 Contents General Information General Machine Description Service Manual Purpose and Application Other Reference Manuals and Information Sources Nilfisk-Advance Publications Engine Manufacturers’ Technical Manuals Introduction Parts And Service Name Plate General Safety Instructions Hopper Safety Support Jacking The Machine...
Page 3 Service Manual – SW8000 Main Controller Error Codes Removal and Installation Main Control Board Specifications Sample Shop Voltage Measurements Dust Control System Functional Description DustGuard™ Spray System (optional) Dust Control Vacuum System Circuit Description Simplified Schematic Diagram Component Locations Maintenance and Adjustment...
Page 4 Service Manual – SW8000 Overview Engine Description Manufacturers’ Technical Literature Engine Starter Circuit Starter Circuit Description Engine Protection – Low Oil Pressure Shutdown Engine Speed Control Glow Plug Control Component Locations Maintenance and Adjustments Maintenance Schedule Engine Oil Engine Coolant...
Page 5 Service Manual – SW8000 Engine Vacuum Special Tools Hopper System Functional Description Overview Hopper Hopper Door Hopper Hydraulic System Hopper System Wiring Diagram Hopper System Circuit Description Hopper System Hydraulic Diagrams Hopper Down, Hopper Door Closed Raise Hopper Lower Hopper...
Page 6 Service Manual – SW8000 Hydraulic Manifold Assembly Special Tools Hydraulic Schematic, 56507055, Rev. L Options and Accessories SW8000 Deluxe Cab Options Technical Specifications Cab Controls Heating System Components Air Conditioning System Components Maintenance Maintenance Schedule To Clean and Replace the Cab Filter...
Page 7 Service Manual – SW8000 Sweep System, Main Broom Functional Description Circuit Description Hydraulic Operation Component Locations Maintenance and Adjustment Cleaning and Inspecting the Main Broom Rotate or Replace the Main Broom Inspect and Adjust the Broom Height Inspect Housing Skirts...
Page 8 Service Manual – SW8000 viii Adjustments To Set the Drive Pump Neutral Position Troubleshooting Specifications...
Page 9: General Information
General Information General Machine Description The SW8000 machine is an industrial power rider broom sweeper. Gasoline (Petrol), LPG and diesel engine models are available, with or without the DustGuard™ option. The machine is hydraulic powered and electrically controlled. The sweep system has a center main broom and a right-hand side brooms. A left hand side broom is available as an option.
Page 10: Parts And Service
Unit Nameplate Location The Model Number and Serial Number of your machine are shown on the Nameplate on the machine. The Model Name imprinted on the nameplate will be SW8000 and the Part Number will correspond to engine type and options on the machine (example: “56107503”). This information is needed when ordering repair parts for the machine. Use the space below to note the Model Number and Serial Number of your machine for future reference.
Page 11: General Safety Instructions
Service Manual – SW8000 General Information General Safety Instructions Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm. Warning! − This machine emits exhaust gases (carbon monoxide) that can cause serious injury or death, always provide adequate ventilation when using machine. − This machine shall be used only by properly trained and authorized persons.
Page 12: Hopper Safety Support
Service Manual – SW8000 General Information − Turn the key switch off and remove the key, before changing the brooms, and before opening any access panels. − Take precautions to prevent hair, jewelry, or loose clothing from becoming caught in moving parts.
Page 13: Jacking The Machine
Service Manual – SW8000 General Information The Hopper Safety Support must be engaged whenever personnel are working on or underneath the hopper. The safety support prevents the hopper from being lowered, or from dropping down accidentally if there’s a failure in the hydraulic system. The Hopper Safety Support Handle operates the Hopper Safety Support. To engage the Safety Support: 1. Raise the hopper to its full-up...
Page 14: Transporting The Machine
Service Manual – SW8000 General Information Transporting The Machine Caution! Before transporting the machine on an open truck or trailer, make sure that . . . − All access doors are latched securely. − The machine parking brake is set.
Page 15: Towing Or Pushing A Disabled Machine
Service Manual – SW8000 General Information Towing Or Pushing A Disabled Machine Caution! The machine’s drive propelling pump is manufactured with an adjustable tow valve. This valve prevents damage to the hydraulic system when the machine is being towed/pushed short distances without use of the engine. To access the valve; unlatch and open the Oil Reservoir / Fuel Tank Cover, then open the Engine Compartment Cover and locate the hydrostatic pump at the rear of the engine.
Page 16: Technical Specifications
Service Manual – SW8000 General Information Technical Specifications General Specifications common to All Models English (Metric) Dimensions Height w/Overhead Guard Height Front View Side View Width Length Front View Side View Length 95 inches (2241 cm) Width (minimum)* 64 (163cm)
Page 17 Service Manual – SW8000 General Information Technical Specifications Hopper System Capacity 14 ft (396L) Lifting capacity 1000 lbs. (454kg) Dump height (variable) Max. 60 inches (152cm) Dump height with door open 52.75 inches (134cm) Dust Control System Filter type: Pleated paper panel STD (optional poly filter...
Page 18: Fastener Torque Specifications
Service Manual – SW8000 General Information Fastener Torque Specifications Size Plated Steel Stainless Steel 42 in.-lb. 28 in.-lb. 1/4“ 100 in.-lb. 67 in.-lb. 5/16” 17 ft.-lb. 11 ft.-lb. 3/8” 31 ft.-lb. 20 ft.-lb. Standard Torque 1/2” 75 ft.-lb. 50 ft.-lb.
Page 19: Maintenance
Service Manual – SW8000 General Information Maintenance Maintenance Schedule Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often. Maintenance Item Perform Daily Perform the “After Use” maintenance steps Check parking brake *Clean main and side broom(s) Check filter indicator and lights (hyd &...
Page 20: To Shut Down The Diesel / Gasoline Engine
Service Manual – SW8000 General Information To Shut Down The Diesel / Gasoline Engine 1. Turn all controls to the OFF position. 2. Raise the brooms. 3. Place the Engine Speed Switch in IDLE and let the engine idle for 25 - 30 seconds. 4. Turn the Ignition Key Switch OFF and remove the key. 5. Apply the Parking Brake. To Shut Down The Propane Engine 1. Turn all controls to the OFF position. 2. Raise the brooms. 3. Turn the service valve on PROPANE Tank OFF. 4. Run the engine until all the PROPANE is dispelled from the line (the engine will stall). 5. Turn the Ignition Key Switch OFF and remove the key.
Page 21: Engine Oil - Gasoline / Petrol & Lpg
Service Manual – SW8000 General Information Caution! Do not use a pressure washer on the raditor or hydraulic oil cooler. Doing so may bend the cooling fins reducing cooling capability. Service Note: The oil cooler tips out for easy cleaning.
Page 22: Engine Air Filter
Service Manual – SW8000 General Information Engine Air Filter The engine Air Filter is located in the engine compartment. Check the air mechanical vacuum filter Service Indicator before each use of the machine. Do not service the air filter unless the indicator is shown (red). Caution! When servicing the engine air filter elements, use extreme care to prevent loose dust from entering the engine. Dust can severely damage the engine. The engine air filter contains a Primary (outer) and a Safety (inner) filter element. The Primary Element may be cleaned twice before being replaced. The Safety Element should be replaced every third time that the Primary Filter Element is replaced. Never attempt to...
Page 23: Hopper Dust Control Filter (Panel Filter)
Service Manual – SW8000 General Information Hopper Dust Control Filter (Panel Filter) The hopper dust control filter must be cleaned regularly to maintain the efficiency of the vacuum system. Follow the recommended filter service intervals for the longest filter life. Caution! − Wear safety glasses when cleaning the filter. − Do not puncture the paper filter. − Clean the filter in a well-ventilated area. − Wear appropriate dust mask to avoid breathing in dust.
Page 24: Sw8000 Pm Checklist
Service Manual – SW8000 General Information SW8000 PM Checklist Defect Codes A Needs Adjustment Customer _________________________________________________ B Binding Dirty or Contaminated Address __________________________________________________ D Damaged, Bent or Torn L Leaks City ________________________________ St __________ Zip ______ M Missing W Worn Out Model __________________ Serial_________________ Hours ______...
Page 25 Service Manual – SW8000 General Information Main Broom Motor (open left side access door to inspect) Broom Housing & Door Skirts Front tires (check lug nut torque 80FT LB, 108 Nm) Battery Engine Air Cleaner Element (inner & outer) Circuit Breaker/Relay panel (inspect electrical...
Page 26: Know Your Machine
Service Manual – SW8000 General Information Know Your Machine Refer to these pages whenever necessary to pinpoint the location of an item mentioned in this manual. Shaker Assembly Retainer Hopper Dust Knobs Control Filter (Dust Filter Shaker Assembly Side Broom below filter) Height Adjustment Engine Knob Compartment Cover Center Cover Assembly Tie-Down Locations (5) Left Side Main...
Page 27 Service Manual – SW8000 General Information Engine Compartment Cover Hopper Cover Prop Rod Tie-Down Locations (5) Right Side Main Broom Access Panel Fuel Tank Cover Release Latch Oil Reservoir / Fuel Tank Cover Oil Reservoir (LPG tank shown / Gasoline /...
Page 28: Operator's Compartment
Service Manual – SW8000 General Information Operator’s Compartment Main Broom Adjust Knob Steering Wheel Main Broom Lever Control Panel Operator’s Hopper Safety Brake Pedal / FWD / REV Seat Parking Brake Drive Pedal Support Handle (Operator Seat Adjustment Circuit Breaker Panel...
Page 29: Control Panel
Service Manual – SW8000 General Information Control Panel Horn Switch Fuel Gauge (Not LPG) Propane Low Indicator Check Engine Indicator Glowplug Indicator (Diesel Only) Headlight Switch Engine Speed Switch Side Broom Switch Dust Control Vacuum Switch Shaker Switch Raise Hopper Switch...
Page 30: Control System
Service Manual – SW8000 Control System Functional Description The SW8000 utilizes a main machine controller to turn on various machine functions. It receives sensor inputs and operator inputs, and activates various solenoids and components. The main machine controller is separate from the engine controller. The only engine function controlled by the main machine controller is the engine speed.
Page 31 Service Manual – SW8000 Control System Ignition (key) Switch (A): The ignition switch serves as a main control switch for the machine and for starting the engine. The key is removable to prevent unwanted operation when not in use. For diesel engines, it also controls the function of the glow plugs. Hour Meter (B): The hour meter shows the run-time on the engine, and it use for tracking maintenance tasks.
Page 32 Service Manual – SW8000 Control System Hopper Up Indicator (M): Illuminates when the hopper mechanism is not in the lowered position. Hopper Over-temp Indicator (N): This lamp illuminates if the hopper temperature exceeds 140˚F (60˚C), due to ingestion of combustible materials or embers. Open Dump Door Switch (O): Opens the dump door for emptying the hopper. Close Dump Door Switch (P): Closes the dump door after emptying the hopper.
Page 33: Main Machine Controller
Service Manual – SW8000 Control System Main Machine Controller The Main Machine Controller (A2) is the primary electronic control for the machine and its functions (except engine control). The control board is the basic input/output device and contains a micro-controller chip to regulate function. The controller receives and interprets user inputs and sensor inputs, and controls device output for the user display, solenoid operation, and motor control.
Page 34: Component Locations
Service Manual – SW8000 Control System Component Locations The diagram below shows component locations for some components related to the Main Machine Controller. • Main Machine Controller • DustGuard and Signaling Switches • Hydrostatic Drive Position Sensor • Engine Controller...
Page 35: Main Machine Controller Programming
Service Manual – SW8000 Control System Main Machine Controller Programming Hydrostatic Neutral Position and Dead-band The purpose of this adjustment procedure is to synchronize the electrical neutral position with the mechanical neutral position of the hydrostatic drive. The mechanical neutral position needs to be adjusted first, and this is where the self-centering drive cable matches the neutral position of the hydrostatic drive. A rotary sensor (potentiometer) reports the position of the drive pump lever to the main machine controller. This procedure records the voltage value of the potentiometer that signifies when the drive is in the neutral position. The dead-band adjustment is the sensitivity of the neutral position. If the dead-band is set too narrow (too sensitive), the controller may believe the drive is in motion, when it is still in neutral, which would prevent engine starting. If set too wide, the drive may be engaged when the controller believes it is in neutral, which...
Page 36: Automatic Shaker Operation
Service Manual – SW8000 Control System Automatic Shaker Operation This adjustment enables or disables the automatic shaker option, and how the shaker functions when it is active in either automatic or manual operation. In either of the 2 automatic modes, the shaker will activate for 15 seconds whenever the broom is raised. Automatic operation in Liberator mode is the default setting. The 3 options are described below: a. Liberator Mode: Automatic operation with manual operation by pressing the shaker switch. When active, the shaker will be on for ½ second and off for ½ second for the 15-second duration of the cycle. b. Continuous Mode: Automatic operation with manual operation by pressing the shaker switch. When active, the shaker will run continuously for the 15-second duration of the cycle. c. Manual Mode: Manual mode only. When the shaker switch is pressed, the shaker will operate continuously for the 15-second duration of the cycle. 1. Make sure the keyswitch is in the off position. 2. While holding the Shaker switch (L), turn the keyswitch (A) to the on position. Continue to hold the Shaker switch until all display indicators turn off (approximately 2 seconds). 3. The Shaker light (L) and Fan Light (K) will indicate the current state of the automatic shaker function, as described below.
Page 37 Service Manual – SW8000 Control System Code Pin # Description Comments • Check coil resistance. † If below 6 Ohms replace (8 J1-3 Side broom solenoid (L3) overload ohms nominal). • Check wiring for a short circuit (Brn/Blk) ‡ • Check coil resistance.
Page 38: Removal And Installation
Service Manual – SW8000 Control System Removal and Installation Main Control Board The main control board and the operator interface may be replaced separately or as an assembly. The same procedure describes either option. Caution! Unswitched battery power is present on the operator interface assembly. Make sure to disconnect the battery connector to avoid damaging the system or wiring.
Page 39: Specifications
Service Manual – SW8000 Control System Specifications Probe Wire Sample Shop Voltage Measurements Examining signals sent and received at the control board can be very effective T-Pin in determining if external components are functioning as expected or if the control board is processing them as expected. The tables below show sample voltage measurements taken from a typical machine. Actual voltages will vary from machine to machine, and with battery charge level. To aid in taking voltage measurements from the cable connectors without removing the connector, a T-shaped push pin connected to the voltmeter probe wire works well (see image to the right).
Page 40 Service Manual – SW8000 Control System Main Machine Controller Sample Voltage Measurements at the J2 Connector Pin # Name V-On V-Off Ref. Comments J2-1 Pedal high 4.12 High voltage reference output of potentiometer 1.72 full fwd J2-2 Pedal wiper 1.31 neutral 1.214 full rev...
Page 41: Dust Control System
Service Manual – SW8000 Dust Control System Functional Description The purpose of the dust control system is to reduce the amount of airborne dust emanating from the machine during sweeping operations. There are two primary stages in controlling dust from the machine. The optional DustGuard™ system sprays a fine mist of water in front of each side broom to minimize the dust...
Page 42: Simplified Schematic Diagram
Service Manual – SW8000 Dust Control System Simplified Schematic Diagram BATTERY, 12 Vdc BATTERY, 12 Vdc STARTER COMMAND CIRCUIT BREAKER, 70 AMP CIRCUIT BREAKER, 70 AMP START ENGINE SYSTEM IGN. SW INPUT SWITCH, IGN. SWITCH, IGN. CIRCUIT BREAKER, 20 AMP...
Page 43: Component Locations
Service Manual – SW8000 Dust Control System Component Locations The diagram below shows component locations for some components related to the dust control system. • Dust Filter • Vacuum Motor • DustGuard Nozzles • Plugged Filter Switch • Shaker Motor • Dust Hopper • Hopper Temp Switch • Misting Pump...
Page 44: Maintenance And Adjustment
Service Manual – SW8000 Dust Control System Maintenance and Adjustment Dustguard Spray Nozzle Cleaning 1. For easier access to the nozzles, raise the hopper slightly. 2. Place a container underneath the nozzles to catch any water that may leak from the hoses. 3. While holding the nozzle body (4) from turning (7/8" wrench) rotate the nozzle cap (1) 1/4-turn and remove the nozzle cap, nozzle tip (2), and check valve strainer (3).
Page 45: Troubleshooting
Service Manual – SW8000 Dust Control System Troubleshooting Dust Control Vacuum Motor will not Run The dust control hydraulic solenoid valve is normally-active (on when no power is present). So the most likely cause is a hydraulic problem, but may also be electrical. Isolate the cause using the following steps: Note: In the decision tree below, all function prerequisites are assumed to be true for the function to normally be active.
Page 46: Dust Control Vacuum Motor Will Not Shut Off
Service Manual – SW8000 Dust Control System Dust Control Vacuum Motor will not Shut Off The dust control vacuum motor should turn off while the shaker is running or when the dust control system is disabled. Failure to turn off is an indication that the bypass solenoid valve is not being activated. The most likely cause is electrical, but may also be from a stuck solenoid valve. Use the following steps to isolate the cause: Note: In the decision tree below, all function prerequisites are assumed to be true for the function to normally be active.
Page 47: Shaker Motor Will Not Run
Service Manual – SW8000 Dust Control System Shaker Motor will not Run If the shaker motor does not operate when the switch is pressed, use the follow steps to isolate the cause: Note: In the decision tree below, all function prerequisites are assumed to be true for the function to normally be active. Shaker motor will not run when switch is pressed...
Page 48: Misting Pump Will Not Run
Service Manual – SW8000 Dust Control System Misting Pump will not Run Operation of the misting pump relay coil has two dependencies. The misting pump switch must be closed for positive voltage at the relay coil, and the controller output for the side broom provides the negative voltage at the coil. If the side broom is functional and in motion, then the controller is known to not be the cause of the problem. If the side broom is not functioning, then troubleshoot the side broom first. Use the following steps to isolate the cause. Misting pump will not run...
Page 49: Specifications
Service Manual – SW8000 Dust Control System Specifications Parameter Range • 85 Ω Misting pump relay coil resistance • 90 Ω Shaker motor relay coil resistance • 85 Ω Dust control (misting) valve coil resistance • 6 Ω Dust control (vacuum) valve coil resistance...
Page 50: Electrical System
Service Manual – SW8000 Electrical System Functional Description Overview The electrical system consists of the switches, gauges and relays on the instrument panel, the circuit breakers, the drive pedal rotary sensor and the battery. Note that the hydraulic solenoid valves and engine electrical components are described in the corresponding sections of this manual. Gauge Panel Assembly...
Page 51: Circuit Breaker Panel Assembly
Service Manual – SW8000 Electrical System Circuit Breaker Panel Assembly assembly is Circuit Breaker Panel mounted below the instrument panel hopper switches and includes the Circuit and the Breakers SPDT Relays Note that diesel models have an additional SPDT Relay Models equipped with the DustGuard ™...
Page 52: Wire Identification
Service Manual – SW8000 Electrical System Wire Identification Wires are color coded and have connector information printed near each end of the wire. • In the bottom left photo, one side of the blue/black wire goes to the Shaker Relay, . The other side of the wire goes to terminal on Circuit Breaker • In the bottom right photo, one side of the gray/blue wire goes to pin on the A2 Main Machine J1-17 Controller.
Page 53: Seat Switch Circuit Description
HEATER TEMP. VIO/GRA CONTROL A-08898 M6/M9 DEL: T A-08928 UPDATE: SHEET 1 & Service Manual – SW8000 Electrical System MAIN MACHINE CON ASSEMBLY, RELAY RED/WHT 1 BLOWER MOTOR FOR MOTOR, BLOWER MOTOR PRESSURIZED AND HEATED CAB, RELAY .5 SEC DELA...
Page 54: Component Locations
Service Manual – SW8000 Electrical System Component Locations The following components are included in this section: • Battery • Instrument Panel Assembly • Circuit Breakers • SPDT Relays • K11 Seat Relay Coil and K12 Timer Relay • S22 Brake Switch • Rotary Sensor Battery is mounted on the left- Battery hand side of the machine frame, just behind the left front wheel.
Page 55: Instrument Panel Assembly
Service Manual – SW8000 Electrical System Instrument Panel Assembly A2 Main Machine Controller Hour Meter are mounted Hour Starter Switch Meter on the A2 Main Panel Assembly Machine Note that Gas and Diesel Controller models also have a Fuel Level Gauge mounted on the...
Page 56: Spdt Relays
Service Manual – SW8000 Electrical System SPDT Relays (single pole, double throw) SPDT Relays mounted on the back of the Circuit Breaker Panel located below the instrument panel hopper switches. Circuit Breaker Note that diesel models have an additional (typical) SPDT Relay Additional are also installed on...
Page 57: S22 Brake Switch (Seat Switch Option Only)
Service Manual – SW8000 Electrical System S22 Brake Switch (seat switch option only) is located S22 Brake Switch adjacent to the and is Brake Pedal actuated when the parking brake is engaged. S22 Brake Switch Rotary Sensor is fastened to Rotary Sensor the mount plate, which is mounted...
Page 58: Electrical Connectors
Service Manual – SW8000 Electrical System Electrical Connectors The following tables list the machine components and their assigned connector or relay, and the individual connector pin-out assignments. The tables include connector illustrations Connector Pin-out Assignments to help you identify the various connectors on the machine.
Page 59: Component To Relay Id Look-Up Table
Service Manual – SW8000 Electrical System Component to Relay ID Look-up Table Component Name Relay ID Horn Relay Lights Relay Shaker Relay Neutral Relay Signal Lights Relay Seat Relay 0.5 Second Delay Relay Connector Pin-out Assignments Connector J1, A2 Main Machine Controller – Molex Mini Fit Jr. 39012205...
Page 60 Service Manual – SW8000 Electrical System Connector J2, A2 Main Machine Controller – Molex Mini Fit Jr. 39012145-14 Pin# Component Assignment Wire Color J2-1 Drive Pedal Sensor, 5K Ohm (3), 5v Reference YEL/GRA 18-1 J2-2 Drive Pedal Sensor, 5K Ohm (2), Wiper...
Page 61 Service Manual – SW8000 Electrical System Shaker Relay, K3 – Tyco 1393310-4 Neutral Relay, K4 – Bosch 3334485007 Pin# Wire Color Pin# Wire Color BLU/BLK 12-1 RED/GRN 16-1 YEL/RED 18-1 GRA/WHT 18-1 BLU/GRN 12-1 – VIO 18-1 BLU/PINK 16-1 VIO 16-4...
Page 62 Service Manual – SW8000 Electrical System 0.5 Second Delay Relay, K12 – Cobo 30-16-07811 Pin# Wire Color RED/BLK 18-2 RED/BLK 18-3 BLK 18-38 BLK 18-39 ORN/GRN 16-1 RED/YEL 18-1 RED/YEL 18-2 Engine System Connector, X1 – Delphi 15326868 Pin# Component Assignment...
Page 63 Service Manual – SW8000 Electrical System Engine System Connector, X2 – Delphi 15326863 Pin# Component Assignment Wire Color – – – – – Coolant Temperature Output TAN 18-1 – – – Throttle Input (12V for high) GRA/BLU 18-1 – –...
Page 64 Service Manual – SW8000 Electrical System Two-pin Connectors – Delphi 12010973 Name Pin# Wire Color PINK/YEL 16-1 Fuel Pump BLK/RED 16-1 RED/BLK 18-1 Hopper Interlock Switch, S4 BLK 18-6 18-6 ORN/BLK 18-1 Main Broom Switch, S2 BLK 18-7 Three-pin Connector – Delphi 12162182...
Page 65 Service Manual – SW8000 Electrical System Two-pin Connectors – Deutsch DT06-2S Name Pin# Wire Color VIO 18-4 L1 - Hopper Door Close/Open Valve, S1 BLU/WHT 18-1 VIO 18-7 L2 - Main Broom Valve, S2 GRN/GRA 18-1 VIO 18-8 L3 - Side Broom Valve, S3...
Page 66: Troubleshooting
Service Manual – SW8000 Electrical System Troubleshooting Problem Cause Correction No power to the Discharged battery. Check the battery voltage and charge as necessary. machine Poor battery connection(s). Check the battery cables, terminals and connections and tighten/repair/replace as necessary. Battery needs to be replaced.
Page 67: Wiring Diagrams, P/N 56382530, Rev. D
Wiring Diagrams, p/n 56382530, Rev. D CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC., PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 68 Service Manual – SW8000 Electrical System Wiring Diagrams, p/n 56382530, Rev. D, sheet 2 of 3 GRN/RED GLOW PLUG SIGNAL J1-11 (ACC INPUT) J2-6 GRN/RED (DIESEL ENGINE ONLY) FROM IGNITION PINK BLU/WHT (IGN. INPUT) J2-11 PINK J1-1 CIRCUIT VALVE S1, HOPPER CLOSE/OPEN...
Page 69 Service Manual – SW8000 Electrical System Wiring Diagrams, p/n 56382530, Rev. D, sheet 3 of 3 KUBOTA DIESEL ENGINE SYSTEM BATTERY, 12 Vdc CIRCUIT BREAKER, 70 AMP BLU/PINK BLU/PINK RED/GRN RELAY, NEUTRAL GLOW (CLOSED IN NEUTRAL) PLUGS GRN/RED CIRCUIT BREAKER, 15 AMP STARTER SWITCH, IGN.
Page 70: Wiring Diagram, Kubota Gasoline Engine, P/N 56107658, Rev
Service Manual – SW8000 Electrical System Wiring Diagram, Kubota Gasoline Engine, p/n 56107658, Rev. A.
Page 71: Wiring Diagram, Kubota Lp Engine, P/N 56107659, Rev
Service Manual – SW8000 Electrical System Wiring Diagram, Kubota LP Engine, p/n 56107659, Rev. A.
Page 72: Wiring Harness Diagrams, P/N 56382531 Rev. D
Wiring Harness Diagrams, p/n 56382531 Rev. D CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC., PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.
Page 73 KUBOTA ENGINE SYSTEM REFERENCE: 56107658 - DIAGRAM-WIRING KUBOTA GAS 56107658 - DIAGRAM-WIRING KUBOTA LP Service Manual – SW8000 Electrical System Wiring Harness Diagrams, p/n 56382531 Rev. D, sheet 2 of 3 KUBOTA DIESEL ENGINE SYSTEM GRN/BLK 16-1 SWITCH, IGNITION RED 10-1...
Page 74 Service Manual – SW8000 Electrical System Wiring Harness Diagrams, p/n 56382531 Rev. D, sheet 3 of 3 CONFIDENT THIS DRAWING AND THE DESIGN REPRESENTED HEREO PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WIT DUCED NOR COPIED NOR USED FOR ANY PURPOSE OT AGREES TO RETURN IT UPON REQUEST.
Page 75: Engine System, Diesel
Service Manual – SW8000 Engine System, Diesel Functional Description Overview The diesel SW8000 machines use a Kubota V-1505-E3B four-cylinder diesel engine to power the two hydraulic pumps that run the machine drive wheel motor, main and side brooms, vacuum fan motor, side broom hydraulic cylinder, hopper lift cylinder, hopper door cylinder and the steering system.
Page 76: Manufacturers' Technical Literature
Service Manual – SW8000 Engine System, Diesel Manufacturers’ Technical Literature Also refer to the following manufacturer’s technical literature when servicing or repairing the engine: • Kubota 05 Series Service Data Book 9Y110-00051.pdf • Workshop Manual, Diesel Engine, 05 Series, WG1605 9Y111-06610.pdf • Woodward Product Specification 03399, APECS...
Page 77: Engine Protection - Low Oil Pressure Shutdown
Service Manual – SW8000 Engine System, Diesel Engine Protection – Low Oil Pressure Shutdown Battery 12 VDC Circuit Breaker, 70 Amp Ignition Switch APECS 3000 Acc. Controller ORN/GRN PINK B (+) B (-) Circuit Breaker, 10 Amp Connect to Pin J1-17...
Page 78: Glow Plug Control
Service Manual – SW8000 Engine System, Diesel Glow Plug Control Battery 12 VDC Circuit Breaker, 70 Amp GRN/RED Starter GRN/RED Ignition Switch The engine is equipped with glow plugs to assist starting a cold engine. The provides voltage to the Battery when the , is in the engine-run position. Glow Plugs Ignition Switch The glow plugs have an internal resistive element that increases in resistance as it heats up.
Page 79: Component Locations
Service Manual – SW8000 Engine System, Diesel Component Locations The following components are included in this section: • Coolant Temperature Switch • Alternator • Oil Pressure Switch • Starter • Air Cleaner • Engine RPM Sensor • Woodward APECS™ Controller • Woodward APECS™ Actuator • Fuel Filter Coolant Temperature Switch Pressure Switch Alternator Starter...
Page 80 Service Manual – SW8000 Engine System, Diesel Cleaner Woodward Engine ™ APECS Controller Sensor Woodward ™ APECS Actuator Fuel Filter...
Page 81: Maintenance And Adjustments
Service Manual – SW8000 Engine System, Diesel Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the parking brake is engaged, key switch is off and the key is removed from the machine. Maintenance Schedule Item...
Page 82: Engine Oil
Service Manual – SW8000 Engine System, Diesel Engine Oil Check the engine oil level when the machine is parked on a level surface and the engine is cool. Change the engine oil and oil filter after the first 50 hours of operation, then every 200 service hours after that. Use CF, CF-4 or CG-4 oil meeting API specifications and suited temperatures. * Important: Refer to the Diesel Lubricating Oil Note below for further diesel oil recommendations. Refer to the engine manufacturer’s service manuals for oil capacities and additional engine specifications. Replace the oil filter with every oil change. Temperature Range Oil Weight Above 77 °F (25 °C) SAE 30 or 10W-30 32 °F to 77 °F (0 °C to 25 °C) SAE 20 or 10W-30 Below 32 °F (0 °C)
Page 83: Replacing Engine Coolant
Service Manual – SW8000 Engine System, Diesel Replacing Engine Coolant One possible cause of engine overheating is trapped air in the cooling system. It’s recommended that you use a Cooling System Tool when changing the engine coolant. The Cooling System Tool pulls a vacuum on the cooling system prior to filling to prevent air from being trapped in the cooling system. Note that there are several types of Cooling System Tools. The following instructions describe how to use a typical type of tool. Refer to the operating instructions included with your particular tool if different than the...
Page 84: Engine Air Filter Maintenance
Service Manual – SW8000 Engine System, Diesel Engine Air Filter Maintenance Caution! When servicing the engine air filter elements, use extreme care to prevent loose dust from entering the engine. Dust can severely damage the engine. The engine air filter contains a primary (outer) and a safety (inner) filter element. The primary element can be cleaned twice before being replaced.
Page 85: Bleeding The Fuel System
Service Manual – SW8000 Engine System, Diesel 2. Unscrew the from the Fuel Filter Fuel Filter Housing 3. Pre-fill the new with clean diesel Fuel Filter fuel to minimize the amount of air that will need to be bled out of the fuel system.
Page 86 Service Manual – SW8000 Engine System, Diesel 4. Slightly loosen the on top of the Bleed Screw to remove the air from the fuel line Fuel Filter Fuel Filter 5. When no more bubbles can be seen at the Fuel...
Page 87 Service Manual – SW8000 Engine System, Diesel Service Note: Normally steps 9 through 17 below are not required to bleed the fuel system. If you do need to perform these steps to bleed the fuel system at the injector pump fittings and injector fittings, make sure to follow the safety warning information below. Warning! If you need to bleed the fuel system at the injector pump fittings or injector fittings as outlined in steps 9 through 17 below, make sure to wear protective gloves to protect your hands from the high-pressure diesel fuel present at these fittings.
Page 88: Troubleshooting
Service Manual – SW8000 Engine System, Diesel Troubleshooting Note: Also refer to the Workshop Manual, Diesel Engine, 05 Series, WG1605 9Y111-06610.pdf for additional troubleshooting information and procedures. General Troubleshooting Problem Cause Correction The engine will not The drive pedal is not in Make sure the drive pedal is in its neutral position.
Page 89: Engine Overheating Problems
Service Manual – SW8000 Engine System, Diesel Engine Overheating Problems When the Coolant Temperature Switch S8 senses that the coolant temperature is too high, it grounds out the wire to the MIL INPUT J2-5 input on the A2 Main Machine Controller. The A2 Main Machine Controller then lights the Engine Service Indicator light on the control panel. Use the checklist below as a guide to thoroughly check the engine cooling system. • Check the coolant level in the overflow tank and radiator. • Inspect and clean the radiator and hydraulic oil cooler. • Check for correct operation of the belt-driven engine cooling fan (slippage). • Check to see that the engine thermostat opens. • Check for correct water pump operation.
Page 90: Compression Test
Service Manual – SW8000 Engine System, Diesel Compression Test Note: The photos shown in this section are from a similar three-cylinder diesel. 1. Begin with a fully-charged battery. 2. Remove the air cleaner assembly. 3. Cover the air inlet opening to prevent foreign objects from falling into the engine. 4. Remove the glow plug Electrical Connector Electrical Nuts Connector “Rail” Connector Nuts Connector “Rail”...
Page 91 Service Manual – SW8000 Engine System, Diesel 8. To test the compression of one of the cylinders, screw in an appropriate adapter into the glow plug threads in the cylinder head and attach a suitable compression gauge. Pictured are Snap-On Diesel ® Compression gauge used with compression test adapter fitting and coupler EEPD500 TU-15-35 M3569 ® Snap-On EEPD500 ®...
Page 92: Specifications
Service Manual – SW8000 Engine System, Diesel Specifications Kubota V-1505 -E3B Diesel Engine Type Water cooled, four-cylinder, four-stroke diesel engine Displacement 91.41 cubic inches [1.498 L] Bore and Stroke 3.07” x 3.09” [78 mm x 78.4 mm] Compression Ratio 22:1...
Page 93: Special Tools
Service Manual – SW8000 Engine System, Diesel Kubota V-1505 -E3B Diesel Resistance – 2.1K ohms near room temperature Engine RPM Sensor Output while cranking (unplugged) – 3.6 to 3.9 VAC Output at idle (connected) – 14.0 VAC Electrical System Resistance – 3.3 Ohms near room temperature...
Page 94 Service Manual – SW8000 Engine System, Diesel Gauge Coupler If using the Snap-On ® diesel compression EEPD500 Gauge kit TU-15-35 glow plug thread fitting, a coupler must ® and Snap-On be used to join the fitting to the gauge hose. Shown are Snap-On ®...
Page 95: Engine System, Gasoline/Lpg
Service Manual – SW8000 Engine System, Gasoline/LPG Functional Description Overview The gasoline (petrol) and LPG SW8000 machines use a four-cylinder 1.6L Kubota engine to power the two hydraulic pumps that run the machine drive wheel, steering system, side and main broom hydraulic motors, dust control hydraulic motor, and the hopper lift and door cylinders. Note: Also refer to the following manufacturer’s technical literature: • Operator’s Manual WG1605 EG523-89162ENG.pdf...
Page 96: Engine Starter Circuit Description
Service Manual – SW8000 Engine System, Gasoline/LPG The DEPR controls the fuel flow, and provides the correct air/fuel mixture to maintain performance and emissions control. The DEPR uses an internal computer, and fuel pressure and temperature sensors to provide input to the ECM for fuel calculation, fault detection and diagnostics. The Mixer Assembly is a self-contained air/fuel metering device that utilizes a relatively constant pressure drop to draw fuel into the mixer from cranking to full load. The Mixer Assembly is mounted in the air stream, ahead of the ETB. The ETB uses an electric motor, connected to the throttle shaft, to increase or decrease the angle of the throttle blade. The ECM sends electrical signals to the motor in the ETB to increase or decrease the airflow to the engine to control the engine speed. Note: For a more detailed and thorough description of the Gasoline and LPG fuel systems, refer to the Diagnosis Manual ECM System WG1605 9Y110-01760.pdf.
Page 97: Engine Protection - Low Oil Pressure Shutdown
Service Manual – SW8000 Engine System, Gasoline/LPG Crank Starter Solenoid Neutral Relay K4 Drive Pedal Sensor Input = NOT Neutral Main Machine Controller Engine Protection – Low Oil Pressure Shutdown The engine controller monitors the oil pressure switch. If it sees a loss of oil pressure, it will shut down the engine immediately. Engine Protection – High Temperature The engine controller monitors the engine coolant temperature. If the temperature reaches 230 deg. F. (110 deg. C.), it will derate the engine power by 30%. If the temperature reaches 240 deg. F. (115 deg. C.), it will shut down the engine.
Page 98: Component Locations
Service Manual – SW8000 Engine System, Gasoline/LPG Component Locations LPG And Gasoline Engine Common Electrical Components The following components are included in this section: (Most photos are of LPG Engine) • Alternator • Ignition Coils • Electronic Throttle Body • Knock Sensor • Cam Position Sensor • Oil Pressure Switch...
Page 99 Service Manual – SW8000 Engine System, Gasoline/LPG...
Page 100 Service Manual – SW8000 Engine System, Gasoline/LPG Ground Engine Coolant Sensor Figure 4. LPG Engine Shown - Top Figure 5. LPG Engine Shown - Rear, Under Air Cleaner Cam Position Sensor Alternator Pre-Catalyst Sensor Post-Catalyst Sensor Figure 6. Oxygen Sensors...
Page 101: Lpg Only Engine Electrical And Fuel Components
Service Manual – SW8000 Engine System, Gasoline/LPG LPG ONLY Engine Electrical and Fuel Components • Fuel Lockoff Solenoid • DEPR - Direct Electronic Pressure Regulator • LP Dual Stage Pressure Regulator • Mixer Assembly Fuel Lockoff Solenoid Direct Electronic Pressure Regulator (DEPR) LP Dual Stage Pressure Regulator Mixer Assembly...
Page 102: Gasoline (Petrol) Only Engine Electrical And Fuel Components
Service Manual – SW8000 Engine System, Gasoline/LPG Gasoline (Petrol) ONLY Engine Electrical and Fuel Components • Fuel Injectors • Fuel Pump Relay (Inside Engine Fuse/Relay Box) • Gasoline Sensor Interface (On top of fuel tank) • Fuel Pump (On top of fuel tank) Fuel Pump Relay Fuel Injectors Gasoline Sensor Interface Fuel Tank...
Page 103: Maintenance And Adjustments
Service Manual – SW8000 Engine System, Gasoline/LPG Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged. Maintenance Schedule...
Page 104: Engine Oil
Service Manual – SW8000 Engine System, Gasoline/LPG Item Service Interval Every Every Every Every Every Every Every Every 8 hrs 50 hrs 100 hrs 200 hrs 1000 hrs 2000 hrs Year (daily). (weekly) Years Replace intake air line Replace breather hose...
Page 105: Replacing Engine Coolant
Service Manual – SW8000 Engine System, Gasoline/LPG Replacing Engine Coolant One possible cause of engine overheating is trapped air in the cooling system. It’s recommended that you use a Cooling System Tool when changing the engine coolant. The Cooling System Tool pulls a vacuum on the cooling system prior to filling to prevent air from being trapped in the cooling system. Note that there are several types of Cooling System Tools. The following instructions describe how to use a typical type of tool. Refer to the operating instructions included with your particular tool if different than the...
Page 106: Engine Air Filter Maintenance
1.6L and GM 3.0L engines. You will need a new version of the GCP software to work with the Kubota WG1605 engine along with the correlating password. The software, password and installation instructions can all be downloaded from “Customer Zone”at www.advance-us.com. Most or all engine troubleshooting is covered in Kubota manuals. There are some things specific to the SW8000 engine application which are covered here in this manual section such as, engine speed control and engine starter operation. Note: Refer to the Diagnosis Manual ECM System WG1605 9Y110-01760.pdf, for engine troubleshooting information and procedures including all fault code diagnosis.
Page 107: Engine Overheating Problems
Service Manual – SW8000 Engine System, Gasoline/LPG Problem Cause Correction • Check circuit breaker CB5 and reset if necessary. The engine will not No power to the Ign. Switch • Check the continuity from the Ignition Switch to the start.
Page 108 Service Manual – SW8000 Engine System, Gasoline/LPG Specifications WG1605-G-E3 WG1605-L-E3 Model Gasoline fuel LPG fuel Number of Cylinders Four Vertical, water cooled, four-cycle Vertical, water cooled, four-cycle Type Gasoline engine LPG engine Bore × Stroke 79.0 × 78.4 mm (3.11 × 3.09 in.) Total Displacement 1.537 L (93.79 cu.in.)
Page 109: Shop Measurements
Service Manual – SW8000 Engine System, Gasoline/LPG Shop Measurements The following information was gathered by measuring one machine. While the values recorded cannot serve as “true specifications” they may help you recognize what normal looks like and give you some standard of comparison. Engine Vacuum 17.5-18 “HG (59-61kPa)-at warm idle. Measured at approximately 900 ft. elevation LP Fuel Pressure • Primary - Approximately 3 psi (20 kPa) • Secondary - Approximately 1 psi (7 kPa) Ignition Output 30 KV while cranking WaveStar : CKP and CMP Running Page: 1...
Page 110: Special Tools
Service Manual – SW8000 Engine System, Gasoline/LPG Special Tools Diagnostic Communication Cable and software, p/n 56305647 Note: The “Ecom” cable is used but the software on the CD is for the GM engines. New software and a new password must be downloaded from Customer Zone to use on the Kubota engine.
Page 111: Hopper System
Service Manual – SW8000 Hopper System Functional Description Overview The hopper holds the dust and debris swept up by the brooms. A hydraulic cylinder raises the hopper for emptying into a dumpster or other receptacle. A second hydraulic cylinder opens and closes the hopper door to allow the Operator to empty the hopper. The dust control system pulls air from the hopper through the...
Page 112: Hopper Door
Service Manual – SW8000 Hopper System Hopper Door is attached to the Hopper Door . The Hopper Door Pivot Hopper Door Pivot is mounted to the two Side Broom Arm Side Broom to allow the to open Brackets Hopper Door Arm Bracket (2) and close.
Page 113: Hopper Hydraulic System
Service Manual – SW8000 Hopper System Hopper Hydraulic System The hydraulic solenoid valves that control the Hopper Lift Cylinder Hopper Door are in the S5 Hopper Cylinder Hydraulic Up/Down , The S4 Only Manifold Assembly S7 Hopper solenoid valves are electrically...
Page 114: Hopper System Wiring Diagram
Service Manual – SW8000 Hopper System Hopper System Wiring Diagram Battery 12 VDC Circuit Breaker, 70 Amp Ignition Ign. Bat. Switch Acc. Circuit Breaker, 20 Amp GRN/BLU A2 Main Machine Controller BLU/WHT J1-1 Valve S1 Hopper Close/Open RED/GRA J1-5 Valve S5...
Page 115: Hopper System Circuit Description
Service Manual – SW8000 Hopper System Hopper System Circuit Description Positive voltage is provided to hopper solenoid valves when the is on. The Ignition Switch will ground and energize the solenoid valve corresponding to the function selected A2 Main Machine Controller...
Page 116: Hopper System Hydraulic Diagrams
Service Manual – SW8000 Hopper System Hopper System Hydraulic Diagrams Hopper Down, Hopper Door Closed Hopper Dump Cylinder From Hopper Steering Steering Close/Open Hopper Open Main Hopper Captive Plug Hopper Lower From Dust Control 2500 Hopper Up/Down To Oil Cooler...
Page 117: Raise Hopper
Service Manual – SW8000 Hopper System Raise Hopper From Steering Steering Main Broom Hopper Captive Up Bypass Plug Hopper Lower From Dust Control 2500 Hopper Up/Down To Oil Cooler and Filter Hopper Lift Cylinder Raises Hopper Gear Pump 2400 1.02 Reservoir • When the Raise Hopper Switch on the control panel is pressed, the A2 Main Machine Controller energizes...
Page 118: Lower Hopper
Service Manual – SW8000 Hopper System Lower Hopper From Steering Steering Main Broom Hopper Up Captive Bypass Plug From Dust Control 2500 Hopper Hopper To Oil Cooler and Filter Hopper Lift Cylinder Lowers Hopper Gear Pump 2400 1.02 Reservoir • When the Lower Hopper Switch on the control panel is pressed, the A2 Main Machine Controller...
Page 119: Open Hopper Door
Service Manual – SW8000 Hopper System Open Hopper Door Hopper Dump Cylinder Opens Hopper Door From Steering Steering Hopper Close/Open Hopper Open To Oil Cooler and Filter Gear Pump 2400 1.02 Reservoir Note: The hopper door can only be opened and closed manually when the hopper is not down.
Page 120: Close Hopper Door
Service Manual – SW8000 Hopper System Close Hopper Door Hopper Dump Cylinder Closes Hopper Door From Steering Steering Hopper Close/Open Open n To Oil Cooler and Filter Gear Pump 2400 1.02 Reservoir Note: The hopper door can only be opened and closed manually when the hopper is not down.
Page 121: Component Locations
Service Manual – SW8000 Hopper System Component Locations The following components are included in this section: • Hopper • Hopper Interlock Switch • Hopper Lift Cylinder • Hopper Prop Rod • Hopper Door Cylinder • Hydraulic Manifold Assembly and Solenoid Valves Hopper is on the front of the machine Hopper and holds the dust and debris swept up by the brooms.
Page 122: Hopper Lift Cylinder
Service Manual – SW8000 Hopper System Hopper Lift Cylinder is attached to the machine frame Hopper Lift Cylinder and hopper, and raises and lowers the hopper. Hopper Prop Rod must be engaged whenever personnel are Prop Rod Hopper working on or underneath the hopper. The Lift...
Page 123: Hopper Door Cylinder
Service Manual – SW8000 Hopper System Hopper Door Cylinder Hopper Door Cylinder attached to the Hopper Door Hopper Lift Arm Weldment and retracts and extends to open and close the Hopper Door Hopper Door Hopper Hopper Lift Arm Door Weldment Cylinder Hydraulic Manifold Assembly and Solenoid Valves...
Page 124: Troubleshooting
Service Manual – SW8000 Hopper System Troubleshooting Problem Cause Correction The hopper doesn’t The engine is at idle speed. Switch the engine to high speed. rise when the Raise Check the connection between the touch pad switch The Raise Hopper Switch Hopper Switch is panel and pin J3-6 on the A2 Main Machine Controller.
Page 125 Service Manual – SW8000 Hopper System Problem Cause Correction The hopper doesn’t The engine is at idle speed. Switch the engine to high speed. lower when the Lower The Lower Hopper Switch Check the connection between the touch pad switch...
Page 126: Specifications
Service Manual – SW8000 Hopper System Problem Cause Correction The hopper door The Close Dump Door Switch Check the connection between the touch pad switch doesn’t close when is not making connection panel and pin J3-7 on the A2 Main Machine Controller.
Page 127: Hydraulic System
Service Manual – SW8000 Hydraulic System Functional Description Overview The hydraulic powers the traction . The hydraulic powers the Piston Pump Drive Motor Gear Pump Main Broom and the . The also powers the Motor Side Broom Motor(s) Dust Control Vacuum Fan Motor...
Page 128: Hydraulic Pumps
Service Manual – SW8000 Hydraulic System Hydraulic Pumps The engine drives the two hydraulic pumps that Case Drain power the drive wheel To “P” Port to Reservoir and the various system Charge Circuit on Hydraulic To “B” from Filter Manifold...
Page 129: Electrical Schematic
Service Manual – SW8000 Hydraulic System Electrical Schematic Battery 12 VDC Circuit Breaker, 70 Amp A2 Main Machine Controller BRN/WHT J2-1 ORN/GRA J2-2 Ignition Ign. Bat. YEL/GRA Switch J2-3 J1-1 BLU/WHT Drive Pedal Sensor, 5K Ohm Acc. Valve S1 Hopper Close/Open...
Page 130: Component Locations
Service Manual – SW8000 Hydraulic System Component Locations The following components are included in this section: • Hydraulic Piston and Gear Pumps • Hydraulic Manifold Assembly • Hydraulic Oil Reservoir • Oil Filter • Oil Cooler Hydraulic Piston and Gear Pumps The hydraulic Piston Pump are mounted on the Gear Pump...
Page 131: Hydraulic Oil Reservoir
Service Manual – SW8000 Hydraulic System Hydraulic Oil Reservoir is located below Hydraulic Oil Reservoir the Operator seat. The hydraulic oil in Filler Cap is at the correct Hydraulic Oil Reservoir level when it is halfway up the filter Hydraulic Oil screen inside the reservoir filler neck as Reservoir viewed when the is removed. Filler Cap Oil Filter is mounted to the machine...
Page 132: Oil Cooler
Service Manual – SW8000 Hydraulic System Oil Cooler is mounted to the rear of Oil Cooler the engine Radiator Radiator Cooler Maintenance and Adjustments Warning! Before performing any machine maintenance or adjustments, make sure the key switch is off, the key is removed from the machine and the parking brake is engaged.
Page 133: To Change The Hydraulic Oil Filter
Service Manual – SW8000 Hydraulic System To Change the Hydraulic Oil Filter Caution! Make sure the hydraulic system is not under pressure, and that the hydraulic filter and reservoir are cool to the touch before servicing the filter. Make sure you are wearing the appropriate clothing and eye protection when working with or near the hydraulic system.
Page 134: Troubleshooting
Service Manual – SW8000 Hydraulic System Caution! Do not use a pressure washer or a mechanical brush to clean fins since this can damage the fins. If the fins get bent, carefully straighten them to improve cooling performance. 4. Lift the to its upright position and latch it into place.
Page 135: Checking The Gear Pump Pressure
Service Manual – SW8000 Hydraulic System Checking the Gear Pump Pressure Note: There is on the Test Port Gear that can be used to check Pump pressure. Gear Pump Test 1. Connect the pressure gauge to the Port Test Port Gear Pump 2.
Page 136: Checking The Piston Pump Pressure
Service Manual – SW8000 Hydraulic System Checking the Piston Pump Pressure Note: Checking the piston pump hydraulic pressure will require you to assemble the appropriate fittings that will allow you to connect your pressure gauge to a suitable location. Measured Pressure from Machine Condition the Piston Pump Level surface, 70°F ambient temperature, Pedal fully depressed – 700 psi empty hopper and tank.
Page 137: Specifications
Service Manual – SW8000 Hydraulic System Specifications General Specifications Specifications Component System Capacity 11 gal. (41.6 L) Fluid Type SAE 10w-30 motor oil Type – manually-variable displacement piston pump, tow valve included Displacement – 0 to 2.48 CIR Speed – 3600 RPM max.
Page 138: Hydraulic Manifold Assembly
Service Manual – SW8000 Hydraulic System Hydraulic Manifold Assembly S4 Only Installed on Models with Litter Vac Kit Hydraulic Manifold Assembly Solenoid Hydraulic Circuit Function Component Description Valve Hopper Close/Open Solenoid-actuated, 2/2 directional poppet, pilot operated cartridge valve Main Broom...
Page 139: Special Tools
Service Manual – SW8000 Hydraulic System Special Tools Hydraulic test gauge w/connector, 3000 PSI range, p/n 56504516 Flow Meter – rated at 3000 psi and 10 gal./min. (typical shown) Various hydraulic fittings required to connect hydraulic test gauge into hydraulic circuits...
Page 140: Hydraulic Schematic, 56507055, Rev. L
Service Manual – SW8000 Hydraulic System Hydraulic Schematic, 56507055, Rev. L Dual Side Broom Option Side Broom Lift Cyl. Side Broom Lift Cyl. 1.00 x 1.18 x .50 1.00 x 1.18 x .50 25 PSI 25 PSI To Side Side Broom Lift Cyl.
Page 141: Options And Accessories
Service Manual – SW8000 Options and Accessories Description Illustration Left Hand Side Broom Rear Bumper Kit (For Non-Cab models) Tilt Steering Kit...
Page 142 Service Manual – SW8000 Options and Accessories Description Illustration Raised Air Intake Kit for use with Overhead Guard Hopper Temperature Sensor Kit Fire Extinguisher Kit (For Non-Cab models)
Page 143 Service Manual – SW8000 Options and Accessories Description Illustration Hopper Bottom Plate Kit Suspension Seat Kit...
Page 144 Service Manual – SW8000 Options and Accessories Description Illustration DustGuard Premist Kit Seat Belt Kit...
Page 145 Service Manual – SW8000 Options and Accessories Description Illustration Right and Left Side Broom Guard Kits Plugged Filter Switch Kit...
Page 146 Service Manual – SW8000 Options and Accessories Description Illustration Litter Vac Kit Raised Air Intake Kit, without Overhead Guard...
Page 147 Service Manual – SW8000 Options and Accessories Description Illustration Rear Work Light Curb Work Light Work Light Kit The Work Light Kit includes three lights: a Curb Work Light, a Rear Work Light, and a Trouble Light. Trouble Light Back Up Alarm Kit...
Page 148 Service Manual – SW8000 Options and Accessories Description Illustration Overhead Guard Kit Amber Strobe Kit, without Overhead Guard...
Page 149 Service Manual – SW8000 Options and Accessories Description Illustration Amber Strobe Kit, with Overhead Guard Cab Side Mirror Option Raised Air Intake Kit for use with Cab...
Page 150 Service Manual – SW8000 Options and Accessories Description Illustration Amber Strobe Kit for use with Cab...
Page 151: Sw8000 Deluxe Cab Options
Service Manual – SW8000 Options and Accessories SW8000 Deluxe Cab Options The SW8000 Deluxe Cab is available with two levels of environmental control that provide additional comfort and convenience for the Operator, and add additional functionality to the machine. • An optional cab heater is available which includes a pressurized cab with an external air filter. • An optional heating and air conditioning system, along with pressurized cab is available that provides Operator comfort throughout a wide range of ambient temperatures. Technical Specifications 79.5 in (202 cm) without Amber Strobe Kit Total Machine Height with Cab (Refer to Figure below.)
Page 152: Cab Controls
Service Manual – SW8000 Options and Accessories Cab Controls (Refer to Figure 2) 1. Cooling Fan Switch 2. Dome Light 3. Heater A/C Fan Switch 4. Heater Temperature Control 5. A/C On/Off Switch 6. Windshield Wiper Switch Figure 2. Cab Controls...
Page 153: Heating System Components
Service Manual – SW8000 Options and Accessories Heating System Components (Refer to Figure 3) 7. Blower Motor 8. Blower Assembly 9. Heater Core 10. Heater Air Box Assembly 11. Filter 12. Coolant Tube (From Engine Radiator) 13. Cab Filter Cover 14. Heater Hoses 15. Heater Control Assembly 16. HVAC Relay Figure 3. Heating System Components...
Page 154: Air Conditioning System Components
Service Manual – SW8000 Options and Accessories Air Conditioning System Components (Refer to Figure 4) 17. Evaporator-Heater Unit 18. A/C Condenser 19. Binary Pressure Switch 20. A/C Receiver/Dryer 21. A/C Compressor 22. Hydraulic Compressor Motor 23. Air Filter 24. Cab Filter Cover 25. Coolant Tube (From Engine Radiator) 26. Heater Hoses 27. Heater Control Assembly 28.
Page 155: Maintenance
Service Manual – SW8000 Options and Accessories Maintenance Warning! Turn the key switch off and remove the key from the ignition switch before performing any machine maintenance. Maintenance Schedule Maintenance intervals given are for average operating conditions. Machines used in severe operational environments may require service more often.
Page 156: Heating System
Service Manual – SW8000 Options and Accessories Heating System General System Overview The SW8000 cab heating system uses an electronic Heater Control Assembly to direct the appropriate amount of engine coolant to the Heater Core in the Heater Air Box Assembly . The Blower Assembly in the Heater Air Box Assembly blows filtered air through the Heater Core to provide warm air to the cab. A four-port bypass butterfly valve in the Heater Control Assembly, run by a small electric motor, controls the coolant flow to the Heater Core. The Heater Temperature Control in the cab controls the voltage to the valve motor, and uses a feedback potentiometer to sense the position of the butterfly valve. Electrical Circuit Overview Heater Blower Motor The following conditions must be met for the blower motor to function: Positive (+) Voltage • The key switch (S1)must be in either the accessory or ignition position to provide +12 VDC (GRN/BLU...
Page 157: Electrical Troubleshooting
Service Manual – SW8000 Options and Accessories Electrical Troubleshooting Note: Refer to the Electrical Wiring and Ladder Diagrams in the Appendix. Symptom: The heater Blower Motor will not run. The Blower Motor is not working. Is there voltage at each of the three positive terminals Is there 12V at the VIO/GRA Replace the Fan on Fan Switch S30 when Switch S30.
Page 158 Service Manual – SW8000 Options and Accessories Symptom: There is no cab heat, or the cab heat cannot be controlled. Note: Before troubleshooting the heating system, make sure the engine is up to normal operating temperature, the engine coolant is at the recommended level and there are no air locks in the cooling system. (Refer to the To Eliminate Air Locks from the Cooling System subsection.) To Troubleshoot the Valve Assembly Valve Assembly 1. Disconnect the electrical connector from the Valve Assembly. 2. Carefully connect a 12 VDC source to...
Page 159: To Troubleshoot The Heater Temperature Control
Service Manual – SW8000 Options and Accessories To Troubleshoot the Heater Temperature Control There is no Cab heat/the Cab heat cannot be controlled. Is there 12V to the Heater Check the wiring to the Heater Temperature Control (BLK and Temperature Control and repair RED wires)? as necessary.
Page 160: To Eliminate Air Locks From The Cooling System
Service Manual – SW8000 Options and Accessories To Eliminate Air Locks from the Cooling System Air locks (air bubbles) in the cooling system can prevent normal coolant flow to the heater core. One factor that can contribute to the formation of air locks is the fact that the heater cores in the SW8000 cabs are the highest point in the machine’s cooling system. This can make it difficult to purge the air from the system using traditional methods more common to the automotive industry. Cooling System Vacuum Filler One recommended method for removing air locks is to drain the cooling system completely, then refill the system using a cooling system vacuum filler tool. This type of tool uses a Venturi vacuum generator to remove the air from the radiator as it fills the radiator with coolant. Purge the Heater Circuit Another method is to remove the hoses that run from the Valve Assembly to the heater core, fill the hoses with coolant to remove as much air as possible from the heater circuit, reinstall the hoses, then run the machine with the heater on to purge any remaining air from the system. Figure 7 shows the heater hose...
Page 161: Air Conditioning System
Options and Accessories Air Conditioning System Note: Refer to the schematics at the end of this chapter. General System Overview The SW8000 cab air conditioning system uses a Hydraulic Compressor Motor (22), powered by the Gear (Accessory) Hydraulic Pump (28), to run the A/C Compressor (21). The A/C Compressor compresses the refrigerant and transfers the hot, high-pressure refrigerant gas to the A/C Condenser (18) at the rear of the machine which condenses the refrigerant gas into a liquid. The condensed high-pressure liquid refrigerant travels from the A/C Condenser to the A/C Receiver/Dryer (20), then to the expansion valve and evaporator inside the Evaporator-Heater Unit (17) inside the cab. The cold, low-pressure refrigerant gas then returns...
Page 162: Condenser Fan, Thermostat, Pressure Switch And Compressor Motor
Service Manual – SW8000 Options and Accessories Condenser Fan, Thermostat, Pressure Switch and Compressor Motor The following conditions must be met for the air conditioning system to function: Positive (+) Voltage • The key switch must be in either the accessory or ignition position to provide +12 VDC (GRN/BLU wire) to the 20A circuit breaker CB4. • Circuit breaker CB4 must be closed to provide +12 VDC (VIO wire) to the control side (coil) of the HVAC Relay K8. • The 20A circuit breaker CB9 must be closed to provide voltage (RED/VIO wire) to the load side of the HVAC Relay K8.
Page 163: Electrical Troubleshooting
Service Manual – SW8000 Options and Accessories Electrical Troubleshooting Note: Refer to the Cab Electrical Wiring and Ladder Diagrams at the end of this chapter. Symptom: One or both of the Blower Motors will not run. One or both of the Blower Motors will not run. Is there voltage at each of...
Page 164 Service Manual – SW8000 Options and Accessories Symptom: The Blower Motors run but there is no cold air coming out of the Evaporator-Heater Unit. Note: Before troubleshooting the air conditioning system, make sure the system is filled with the recommended amount of refrigerant. We recommend that you have this checked by a qualified technician or an EPA-certified air conditioning repair shop. Note: Refer to the Cab Electrical Wiring and Ladder Diagrams in Appendix, and the Component Troubleshooting subsections on the following pages.
Page 165: Component Troubleshooting
Service Manual – SW8000 Options and Accessories Component Troubleshooting Compressor Motor Hydraulic Valve (L10) (Refer to Figure 8) Note: The Compressor Motor Hydraulic Valve and Hydraulic Pressure Test Port are attached to the tee-fitting off of the Accessory Hydraulic Pump. 1. Disconnect the Electrical Connector from the Hydraulic Valve. 2. Switch on the A/C and check for 12 VDC at the Electrical Connector. 3. Check the coil resistance of the Hydraulic Valve. It should be approximately 7 ohms ±20%. 4. If there is 12 VDC at the Electrical Connector and the coil resistance is within spec, disassemble the Hydraulic Valve and clean or replace the cartridge as necessary.
Page 166: Accessory (Gear) Hydraulic Pump
Service Manual – SW8000 Options and Accessories Accessory (Gear) Hydraulic Pump (Refer to Figure 8) 1. Connect a hydraulic pressure gauge to the Hydraulic Pressure Test Port off of the Accessory Hydraulic Pump. 2. Start the engine, then switch the A/C on and off at the two engine speeds and note the hydraulic pressures at the Hydraulic Pressure Test Port.
Page 167: Binary Pressure Switch (S34)
Service Manual – SW8000 Options and Accessories Compressor Relay (K10) Figure 9. Compressor Relay Warning! High-pressure side air conditioning components, fittings, lines and hoses can be extremely hot after operation and can cause severe burns. Always use the appropriate precautions when working around the Binary Pressure Switch, Receiver/Dryer or other A/C components.
Page 168 Service Manual – SW8000 Options and Accessories Binary Pressure Switch (S34) A/C Receiver/Dryer Figure 10. Checking Continuity through the Binary Pressure Switch...
Page 169: Thermostat (S33)
Service Manual – SW8000 Options and Accessories Thermostat (S33) (Refer to Figure 11) Note: The Thermostat is located inside the Evaporator-Heater Unit in the cab. 1. Remove the top cover/nozzle assembly from the Evaporator-Heater Unit. 2. Remove the front panel from the Evaporator-Heater Unit. 3. Remove the two electrical connectors (BLK/WHT and GRN wires) from the Thermostat and check the continuity across the two terminals. Note: The Thermostat is normally closed and should have continuity across the terminals at ambient temperatures above 31°...
Page 170 Service Manual – SW8000 Options and Accessories Thermostat (S33) Figure 11. Checking Continuity through the Thermostat...
Page 171: Heating And A/C System Plumbing And Hydraulic Flow Schematic
Service Manual – SW8000 Options and Accessories Heating and A/C System Plumbing and Hydraulic Flow Schematic 1. Heater Core 2. AC Evaporator 3. Radiator Coolant Tube 4. Feed Hot Water 5. Return Flow 6. Heater Control Valve 7. Hydraulic Test Port 8. Low Pressure Refrigerant (Gas) 9. High Pressure Gas...
Page 172: Steering System
Service Manual – SW8000 Steering System Functional Description Overview The steering system includes the Steering Wheel Steering Control Unit Steering Cylinder Drive Yoke Weldment rotates the Steering Steering Wheel shaft on the Control Steering Control Unit Unit Steering which controls the oil flow to the Wheel .
Page 173 Service Manual – SW8000 Steering System The “A” port on the Hydraulic Manifold Assembly supplies hydraulic oil to Hydraulic the “P” (pressure) port on Manifold Steering Assembly Steering Control Unit Control The oil from the “T” (tank) Unit port on the Steering Control goes to the “T1” port Unit on the Hydraulic Manifold , then to the oil Assembly cooler, filter and reservoir.
Page 174: Hydraulic Diagrams
Service Manual – SW8000 Steering System Hydraulic Diagrams Steering Control Unit Description uses the input from Steering Control Unit Steering Cylinder Stationary the steering wheel to turn the drive wheel in the appropriate direction to steer the machine. When the Operator turns the steering wheel, the steering wheel shaft rotates the...
Page 175: Steering Wheel Stationary
Service Manual – SW8000 Steering System Steering Wheel Stationary When the engine is running, the sends Gear Pump Steering Cylinder Stationary oil through the flow divider in the 2.0 GPM Hydraulic to the “ ” port on the Manifold Assembly Steering . When the steering wheel is stationary, Control Unit is in its neutral (closed) position.
Page 176: Steering Wheel Turned Toward The Right
Service Manual – SW8000 Steering System Steering Wheel Turned Toward the Right When the Operator turns the steering wheel to Steering Cylinder the right, the directs the hydraulic oil Moves Drive Wheel Rotary Valve to Steer Machine to the corresponding side of the . The Rotary Meter...
Page 177: Steering Wheel Turned Toward The Left
Service Manual – SW8000 Steering System Steering Wheel Turned Toward the Left When the Operator turns the steering wheel to the Steering Cylinder left, the directs the hydraulic oil to the Moves Drive Wheel Rotary Valve to Steer Machine opposite side of the . The Rotary Meter Rotary Meter...
Page 178: Steering Wheel Held In Full Right Or Left Position
Service Manual – SW8000 Steering System Steering Wheel Held in Full Right or Left Position When the steering wheel is held to the stop in its full- Steering Cylinder Stationary right or full-left turn position (full-left is shown here), with Steering Wheel...
Page 179: Turning The Steering Wheel With The Engine Off
Service Manual – SW8000 Steering System Turning the Steering Wheel with the Engine Off When the engine is off and no hydraulic oil is being Steering Cylinder pumped to the , the Moves Drive Wheel Rotary Valve Rotary Meter to Steer Machine...
Page 180: Component Locations
Service Manual – SW8000 Steering System Component Locations The following components are included in this section: • Steering Wheel and Steering Control Unit • Steering Cylinder Steering Wheel and Steering Control Unit rotates the splined Steering Wheel shaft on the...
Page 181: Maintenance
Service Manual – SW8000 Steering System Maintenance Warning! Make sure the steering system and surrounding components are cool to the touch before attempting to grease the steering system components. Failure to observe this safety precaution can result in severe burns.
Page 182: Troubleshooting
Service Manual – SW8000 Steering System Troubleshooting Problem Cause Correction The steering is hard or Not enough oil to the steering Check the pump output and correct as necessary. Check the priority flow divider and correct/replace as “jerky”. system necessary.
Page 183: Sweep System, Main Broom
Service Manual – SW8000 Sweep System, Main Broom Functional Description The hydraulically powered main broom is used to sweep dry debris into the hopper. It can be operated with or without the dust control function, and with or without the side brooms being used. Circuit Description Most control circuits are fairly straight forward with the controller completing the electrical circuits to ground.
Page 184: Hydraulic Operation
Service Manual – SW8000 Sweep System, Main Broom Hydraulic Operation The hydraulic system is controlled by two solenoid valves, which are themselves, controlled by the main machine controller. The solenoids are active when the main machine controller sets the output to a low voltage (connects the output to ground).
Page 185: Component Locations
Service Manual – SW8000 Sweep System, Main Broom Component Locations The diagram below shows component locations for some components related to the main broom system. • Idler Arm • Broom Motor • Broom Controls • Main Broom Switch • Main Broom • Hydraulic Valves Broom Controls...
Page 186: Maintenance And Adjustment
Service Manual – SW8000 Sweep System, Main Broom Maintenance and Adjustment When the machine is not in use, the main broom should be in the raised position to prevent flattening and curling of the bristles. Cleaning and Inspecting the Main Broom Inspect and clean the main broom whenever it is removed for rotation, or if sweeping performance is reduced when the hopper is not full. Remove any twine or other materials that are wound around the broom cylinder or any other debris that prevents good contact between the broom bristles and the cleaning surface.
Page 187: Inspect And Adjust The Broom Height
Service Manual – SW8000 Sweep System, Main Broom Inspect and Adjust the Broom Height The main broom has 2 operating positions; Float (7) and Sweep (6). In the Float position, the height is left uncontrolled (floating) and the pressure on the broom is primarily determined by the weight of the mechanism. Due to the weight of the mechanism, operating the broom in Float mode for extended periods can result in excessive wear of the broom. In Sweep mode, the height of the broom is limited by the adjustment knob (4) to reduce wear on the broom. The main broom adjustment knob (4) must be re-adjusted as bristle material is worn down and when the broom is replaced. Determining whether the broom height needs to be adjusted involves examining the contact area under the broom. 1. Drive the machine to an area with a level floor and set the parking brake. (Preferably an area with a dirty floor that will show contact from the spinning broom.) 2.
Page 188: Troubleshooting
Service Manual – SW8000 Sweep System, Main Broom Troubleshooting Main Broom Motor Will Not Run Perform all testing with the engine running at operating speed, the main broom lowered (Sweep position), and the drive pedal activated (the machine moving). The main broom magnetic switch S2 must be open and the hopper interlock switch S4 must be closed for the main broom system to run.
Page 189: Specifications
Service Manual – SW8000 Sweep System, Main Broom Specifications Solenoid Coil Resistance Values Solenoid Coil Normal Resistance Value S2 coil 8 ohms S6 Coil 8 ohms...
Page 190: Sweep System, Side Broom
Service Manual – SW8000 Sweep System, Side Broom Functional Description The side broom sweep system consists of one or two hydraulically driven rotating brooms at the front corners of the machine. The brooms direct debris to the center of the machine where it can be picked up by the main broom and deposited in the hopper. The brooms are raised and lowered by hydraulic actuators.
Page 191: Electrical Circuit
Service Manual – SW8000 Sweep System, Side Broom Electrical Circuit Most electrical control circuits are fairly straight forward with the controller completing the electrical circuits to ground. The controller will not activate the side brooms unless the main broom is active (and all other prerequisites to that function are also true).
Page 192: Hydraulic Circuit, Brooms On
Service Manual – SW8000 Sweep System, Side Broom Hydraulic Circuit, Brooms On In order for the side brooms to operate, the main broom must be running. The S2 solenoid is energized to allow fluid to flow to the splitter between the main broom and the side broom circuits. The side broom solenoid (S3) is energized to allow fluid to flow into the side broom circuit. This also energizes the piloted control line for V1 and C2 to allow excess fluid to leave the side broom lift cylinders so they can be lowered. If equipped with the optional side broom speed control, fluid flows through the variable flow regulator, and any excess flow not needed for the set speed will return through the low pressure return line. The two side brooms are connected in series. At the first broom, fluid activates the cylinder to lower the broom and flows through the broom motor. The fluid exiting that motor then passes to the second (optional) side broom before returning through the low pressure return line. Side Broom Lift High Pressure Low Pressure Side Broom Side Brooms Lowered,...
Page 193: Component Locations
Service Manual – SW8000 Sweep System, Side Broom Component Locations The diagram below shows the location of the side broom motor, lift cylinder, and hydraulic valves. Hydraulic Valves Side Broom Side Broom Motor Lift Cylinder...
Page 194: Troubleshooting
Service Manual – SW8000 Sweep System, Side Broom Troubleshooting Side Broom Won’t Run Side Broom will not run when the switch is on The side broom cannot operate Verify that the main unless the main broom is running. broom is turning...
Page 195: Side Broom Won't Raise
Service Manual – SW8000 Sweep System, Side Broom Side Broom Won’t Raise If the side broom stops rotating but won’t raise, that is indicative of a hydraulic problem with the pilot controlled valve V1. If the side broom won’t raise and also continues to rotate (with main broom running), that may be either a stuck S3 solenoid or an electrical problem. Side Broom will not raise when off Piloted valve V1 is stuck. Stay lowered when Done Replace the valve. main broom is off? Check for 12 V at side...
Page 196: Wheel System, Non-Traction
Service Manual – SW8000 Wheel System, Non-Traction Functional Description The non-traction wheels support the front of the machine and house the machine brakes. The wheel system includes the Wheels, Brake and Spindle Assemblies and the various mounting hardware. The wheels are mounted in the wheel wells on the front sides of the machine, between the main broom cover panels and the side brooms.
Page 197: To Remove And Reinstall A Brake And Spindle Assembly
Wheel System, Non-Traction Service Manual – SW8000 5. Place the wheel on the spindle and install the five lug bolts to secure the wheel. Torque to 95-105 Ft. lbs. (130 - 140 N m) To Remove and Reinstall a Brake and Spindle Assembly 1. Jack up the machine at a designated jacking point. 2. Install safety stands or blocks to support the machine while you work on it. 3. Remove the Wheel from the Brake and Spindle Assembly. 4. Remove the clevis and yoke holding the Rod End to the Brake Lever. 5. Remove the four 1/2”-20 hex screws and remove the Brake and Spindle Assembly from the machine. 6. Reinstall the Brake and Spindle Assembly by following the above steps in reverse order.
Page 198: Wheel System, Traction
Service Manual – SW8000 Wheel System, Traction Functional Description Overview The traction wheel system includes the piston (drive) pump, hydraulic traction drive motor, foot pedal, and the forward/reverse controls that control the direction and speed of the drive motor. The traction drive motor is driven by the variable-displacement piston pump which allows speed and directional control.
Page 199: Foot Pedal Assembly
Service Manual – SW8000 Wheel System, Traction Foot Pedal Assembly pivots in the to move the Foot Pedal Foot Throttle Plate forward and backward. Lever Weldment Push/Pull Control Cable Foot actuates the Pedal Lever Weldment Push/Pull Control Cable forward/reverse controls connected to the piston (drive) pump.
Page 200: Rear Wheel Assembly
Service Manual – SW8000 Wheel System, Traction Rear Wheel Assembly is bolted Rear Wheel Assembly to the . The Drive Wheel Hub Rear Steering and attached Cylinder Wheel Assembly fit onto the keyed, Drive Wheel Hub tapered shaft on the Drive Motor hold...
Page 201: Hydraulic Diagrams
Service Manual – SW8000 Wheel System, Traction Hydraulic Diagrams Drive Motor in Neutral When the foot pedal is in the neutral position with the engine running, the From Oil Cooler will not send any oil to the and Filter Piston Pump...
Page 202: Drive Motor In Forward Or Reverse
Service Manual – SW8000 Wheel System, Traction Drive Motor in Forward or Reverse When the engine is running and the foot pedal is moved to either the forward or From Oil Cooler reverse position, the sends oil and Filter Piston Pump...
Page 203: Drive Motor Stalling Out
Service Manual – SW8000 Wheel System, Traction Drive Motor Stalling Out If the is unable to run in Drive Motor forward or reverse for any reason (rear From Oil Cooler wheel stalled, etc.), the corresponding and Filter internal relief valve in the...
Page 204: Component Locations
Service Manual – SW8000 Wheel System, Traction Component Locations The following components are included in this section: • Piston (drive ) Pump and Tow Valve • Drive Motor and Rear Wheel Assembly • Foot Pedal Assembly • Forward/Reverse Controls Piston (drive) Pump and Tow Valve (blue) is attached to the Piston Pump front end of the engine.
Page 205: Foot Pedal Assembly
Service Manual – SW8000 Wheel System, Traction Foot Pedal Assembly actuates the Foot Pedal Assembly forward/reverse controls to control machine direction and speed. Foot Pedal Assembly Forward/Reverse Controls The lever weldment push/pull control cable, Lever Lever Weldment Lever Nylon Cam...
Page 206 Service Manual – SW8000 Wheel System, Traction Adjustments To Set the Drive Pump Neutral Position 1. Jack up the rear of the machine to get the drive wheel up off the ground. 2. Install safety blocks or stands to support the rear of the machine. 3. Remove the center cover assembly/DustGuard tank to access the forward/reverse controls. ™ Note: If your machine is equipped with a DustGuard system, you’ll need to disconnect the hose ™...
Page 207 Service Manual – SW8000 Wheel System, Traction Troubleshooting Problem Cause Correction The machine won’t The foot pedal deadband Reset the foot pedal deadband position. start. position is not set correctly. The machine “creeps” The forward/reverse controls Adjust the forward/reverse controls and/or linkage so forward or backward are out of adjustment.

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Nilfisk-Advance SW8000 Service Manual

General Information

Control System

Dust Control System

Electrical System

Engine System, Diesel

Engine System, Gasoline/Lpg

Hopper System

Hydraulic System

Options and Accessories

Steering System

Sweep System, Main Broom

Sweep System, Side Broom

Wheel System, Non-Traction

Wheel System, Traction

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Service Manual

Troubleshooting

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Summary of Contents for Nilfisk-Advance SW8000