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Advance SW8000 Service Manual

1. GRA 18 4 22 GRA 18 8 SP29 A A RED BLK 18 5 GRA 18 9 B B GRA18 6 X66 X17 CONNECT X17 HERE ee S24 SWITCH TURN SIGNAL VIO 18 2 X17 X58 S22 VIO 18 18 RED YEL 18 1 19 RED BLK 18 5 A 1_2 2 SWITCH BRAKE YEL 16 3
2. GANBLK161 00 E KUBOTA DIESEL ENGINE SYSTEM 17 SWITCH IGNITION LLL RED104 00 30 19 GRN BLU 14 1 50 42 n X83 1 INSERT GRN RED WIRE INTO TERMINAL 6 WAY GRN RED 10 1 2 POSITION 6 ON CONNECTOR J2 AT X154 WHT GRN RED 18 2 3 THE CONTROL BOX ASSEMBLY ACTUATOR E 2 RED162 A RED ACTUATOR WHTIBLK 5 D2 BLK 16 13 B BLU 3 5 d 6 2 i Voda C amp MAGNETIC PICKUP BLK 18 3 14 7 2 03 lt SPEED SELECT 1 MAGNETIC PICKUP LGRN 3 R7 SP23 GRA 18 6 D lt D GRA SPEEDSELECT2 YEL 59 S SERVICE TOOL Tx R t 2 2 1 TAN 18 3 T T SERVICE TOOL Rx 3 SWITCH COOLANT TEMP SENDER TEMP APECS 3000 GOVERNOR BLK 18 5 x GRN YEL 18 3 c2 D oeg B y 06 1 E o ob ob o dj c E d S S RED 12 2 E zz T zm L1 2 ix cul du aq ae L5 PINK 16 8 ag E ej im aaa a lt lt a CIR BKR 70 AMP as gt PL gt gt L X142 CC CC Oj MAIN DLP tC croc o o tr S ALTERNATOR m 39 M
3. 54 E E E ee Wo x eee eee E 54 Instrument Panel Assembly cc ee eee ooo hi9 n o onn 55 a qnidsqc lg 55 56 K11 Seat Relay Coil and K12 Timer Relay seat switch 56 522 Brake Switch seat switch 57 ROU v s s mor E RIE 57 Electrical 58 Component to Connector ID Look up 58 Component to Relay ID Look up Table m RR Bor X oo ox o3 RE OE vede ES 59 Connector Pin out Assignments 59 Troubleshooting eee o 4 AR en x P REI P 4 66 AGEUR S keene S REOR eH 6 9 S 66 Wiring Diagrams p n 56382530 Rev 67 Wiring Diagram Kubota Gasoline Engine p n 56107658 Rev 70 Wiring Diagram Kubota LP Engine p n 56107659 71 Wiring Harness Diagrams p n 56382531 72 Engine System 75 Functional Description 75 iii Service Manual SW8000 COVEFVIEM
4. 151 s nu x9 X 9 ee eee eee ee ee eae eee ee eee ee HH ESS E eee Se 152 Heating System 153 Air Conditioning System 154 Mantenan 22424446745 68 24 Euh eg gt 5d 2 155 Maintenance 5 155 To Clean and Replace the 155 Heating s e rasg ae ee ee ee Row paa 156 General System Overview 156 Electrical Circuit Overview 156 Heater Blower Motor 4 e dox aun rex ew a og 156 Heater Temperature 156 Electrical Troubleshooting 157 To Troubleshoot the Heater Temperature Control aaa a 159 To Eliminate Air Locks from the Cooling System 2s 160 Cooling System 160 Purge the Heater Circuit 160 Air Conditioning 161 General System 161 Electrical Crea OVervieW s s s eu bee boca eae ee GREE 161 Condenser Fan Thermostat Pressure Switch and Compressor 162 Electrical Troubleshooting
5. 163 Component 165 Accessory Gear 166 Compressor Relay TO 25555 95 166 Binary Pressure Switch 534 167 Thermostat 5633 169 Heating and A C System Plumbing and Hydraulic Flow 5 171 Steering 172 Functional Description 172 s Ew mu RESP 172 Hydraulic lt 174 Steering Control Unit Description 174 Steering Wheel Stationary s cea ec bwe Sb E 3 ede X GEOP Ck CROR Xo 9 4 175 Steering Wheel Turned Toward the Right 176 Steering Wheel Turned Toward the Left o 177 Steering Wheel Held in Full Right or Left Position ee 178 Turning the Steering Wheel with the Engine 179 Component Locations oaoa 180 Steering Wheel and Steering Control Unit 180 Steering CQVINGE es dede ie Hae x ONE P3 3 9 3 180 Ww Eid aweu Rx eo
6. 103 3 2 2 4 x E Oe 94439 5 59 104 Engine COGIUNES RE WP suum Rus m E NW NEST SEES eue 2 104 checking Engine 104 Replacing Engine Coolant 105 Engine Air Filter Maintenance 106 Troubleshooting nd vow doe ke ROG M mu xa Su PX 3 RG 4 313 106 General Troubleshooting BEERS 106 Engine Overheating lt 107 Shop Measurements 109 Service Manual SW8000 Engine 109 Special TOOLS a ETC 110 HOpDpEr 555552 ROME eR aa OE 111 Functional Description 111 QUA 111 WE X P eee eee mE up x d RE S 111 Hopper DOO 8 40 EX ee eee wee m 112 Hopper Hydraulic 5 113 Hopper System Wiring 114 Hopper System Circuit lt 115 Hopper System Hydraulic 116 Hopper Down Hopper Door 116 PU CHOO
7. Cleaning Hysrauic Oi ReservoirLevel f 1 asoa NEN NI seat a a8 Rete 50 iPFuerRegustrlockOfWawe amp oss J oo 51 Diesel Gow Pug nacar sa Engine Hose Assembly c 54 DustGuard Water Tank Misting Pump amp Storage Tank SiS NOTE For additional service information see service manual form number 56043163 and operators manual form number 56091065 English amp Spanish Defect Codes A Needs Adjustment Dirty or Contaminated M Missing B Binding D Damages bent or torn W Worn Out L Leaks Work Completed By Acknowledged By Service Technical Signature Date Customer Signature Date Sheet 2 of 2 25 Service Manual SW8000 General Information 26 Know Your Machine Refer to these pages whenever necessary to pinpoint the location of an item mentioned in this manual Shaker Assembly Retainer 4 Knobs Hopper Dust 43 Control Filter Dust Filter Shaker Assembly Side Broom below filter Height Adjustment Knob Engine Compartment Cover Center Cover Assembly Tie Down Locations 5 Left Side Main Broom Access Panel Cover Hopper Cover Locations Latch 1 Rear location is large UH p weight below radiator Know Your Machine Ser
8. Introduction This manual will help you get the most from your Advance rider Scrubber Sweeper Read 1t thoroughly before servicing the machine Refer to the Know Your Machine section for component locations discussed in this chapter This product 1s intended for commercial use only Service Manual SW8000 General Information 10 Parts And Service Repairs when required should be performed by your Authorized Advance Service Center who employs factory trained service personnel and maintains an inventory of Advance original replacement parts and accessories Call the ADVANCE DEALER named below for repair parts or service Please specify the Model and Serial Number when discussing your machine Dealer affix service sticker here Name Plate p Unit Nameplate 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 MODEL NUMBER SERIAL NUMBER Caution and Warning Symbols It 15 important for you to read and understand this manual The information it contains relates to protecting your safety and preventing problems The
9. 81 ee 6 WHITE LT 1 p WHITE BROWN 1 AUX PWMS RECIRC 74 GREEN YELLOW 18 BROWN WHITE 16 AUX PWMS ih LM CONNECTOR 2 AUX PWM1 AUX ANA PU2 PED 15326868 CONN AUX ANA PU3 PED 15326269 TERM GOV SELECT 2 PED_ 12191153 SEAL GOV SELECT 1 PED 15305171 CAVITY PLUG AUX 0162 CAP WITH MATING CONNECTOR Bem GNE RED TAN 16 gt 80 PINK WHITE 80 1 B1 BLACK 16 82 TAN ORANGE 18 B3 WHITE BROWN 16 BROWN WHITE 16 85 TAN 16 2 0 o LOCKOFF PED_ 12052641 CONNECTOR PED_ 12048074 TERMINAL PED_ 12052634 LOCK re E n WHITE BLACK 18 ORANGE YELLOW_18 PINK DK GREEN 16 WUADVZECRAOCIAAMONDS 12V RELAYED POWER 015200042 FUSE HOLDER 01520072 COVER 913 087 001 TERMINAL 868 096 SEAL 02990560V FUSE ALTERNATOR DIAGNOSTIC CONNECTOR WITH CLIP _ 12048086 SEAL UNUSED UNUSED UNUSED _ 1F1T 14A624 AA 004 CONN BLACK YELLOW 18 GTS_ 330 930009 TERM 18 20 if required ww O GTS 0330 940001 TERM 14 16 if required EPC E6DB 14A468 DA LOCK EPC 14 666 DEUTSCH 0413 204 2005 PLUG TRW 6476883801 CLIP BLUE PINK 18 KNOCK SENSOR 8 Jj BOSCH 1 928 403 126 CONN 72 R1 STARTER ALTERNATOR CONN 87 UNUSED NU UO PINK DK GREEN 18 SWS
10. Sencor Figure 6 Oxygen Sensors Service Manual SW8000 Engine System Gasoline LPG 101 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 p Ts LP Dual Stage Pressure Regulator Service Manual SW8000 Engine System Gasoline LPG 102 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 A LESE r vsi ALS X wot AL LEITET LI Fuel Pump q Relay agi ef 3 eed Fuel Injectors Gasoline Sensor Interface Service Manual SW8000 Engine System Gasoline LPG 103 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 Item Service Interval ey Every Every Every Every Every Every very 8hrs SOhrs 200hrs 1000 hrs 2000 hrs Year Two daily weekly Years uud x
11. Tyco 1393310 4 Ping Wire Color Tes vio164 Signal Lights Relay K5 Bosch 3334485007 Ping Wire Color Tes vors Electrical System Neutral Relay K4 Bosch 3334485007 Pin wire coor 86 GRAWHT1E3 Seat Relay K11 Bosch 3334485007 Pinf Wire 86 eks 61 Service Manual SW8000 Electrical System 62 0 5 Second Delay Relay 12 Cobo 30 16 07811 Pin wire Color Engine System Connector X1 Delphi 15326868 i i O O O ignition Swich mpos B ExciteonA3 PINK 16 7 2 D Pump Output SY PINK YEL 16 1 F Starter Command BLUPINK163 8 Service Manual SW8000 Electrical System 63 Engine System Connector X2 Delphi 15326863 LB E Name A RED YEL 18 1 Seat Switch S21 B RED BLK 18 4 RED BLK 18 5 X17 Brake Switch 522 A 18 6 A BLU GRN 14 1 X40 Shaker Motor LA B BLK 14 1 Back Up Alarm VIO 18 17 X46 optional GRN BRN 18 1 VIO 18 16 X76 Strobe optional B 18 22 Service Manual SW8000 Two pin Connectors Delphi 12010973 IDD Name Pin WireColor A PINK YEL 16 1 X37 Fuel Pump EM B BLKR
12. _ 178392 6 8MM 171662 5 TERM 172888 2 SEAL RING SUMITOMO 6189 0551 CONN gt 2 BLACK 16 BLACK 16 BLACK 12 BLACK 16 9 OW DK B 8 40 DK BLUE YELLOW 18 TAN DK GREEN 18 44 18 vsw 45 AUX PUD2 46 AUX PUD1 47 PURPLE LT BLUE 18 RED TAN 16 RED 16 RED 12 PURPLE 18 MN AUX DIG 3 GOV2 AUX DIG 4 SV Sv EXT CANI CANI SV RTN2 SV EXT2 PURPLE YELLOW 18 DK BLUE ORANGE 18 BLACK LT GREEN 18 LT GREEN RED 18 LT GREEN BLACK 18 LT GREEN PURPLE 18 3dHit 5 1 48 LT BLUE DK BLUE 18 B CHARGE INDICATION FUELSELECTIAUX DCT 49 GREEN PURPLE 18 USED AUX DIG 2 90 TAN RED 18 DK BLUE 18 E AUK PRM 2 CONNECTOR 1 M EE UNE H SREENCYELLOW 18 G MIL PED_ 15326863 CONN AUX DIG 1 PED_ 12191819 TERM PED 12191153 SEAL BUCkAT GREEN 18 IS 15305171 CAVITY PLUG M N P R S 5 51 BLACK YELLOW 18 TWISTWIRES 10 TURNS 360_DEG ZFOO KNOCK 52 ny 1 53 DK BLUE ORANGE 18 PC TX 9 61 BLACK YELLOW 18 HT 62 BLACK WHITE 18 111 1 _ rmm AL I dl 0 LI VEHICLE INTERFACE CONNECTORS VIC 72 PRK ELACK
13. SOME BLK LAMP REAR WORK CAB OPTION as e LP10 RED 1 2 RED 21608 BLK BLK OPTIONAL FUSE 1A SW SPST SUBLET RMB CB8 K6 87a RED 1 2 BLU 30 87 GRA ORN MY BLK 4 CIRCUIT BREAKER 10 A RE OPTIONAL BEL MISTING PUMP MISTING PUMP OPTIONAL OPTIONAL BLK SEAT SWITCH OPTION 12V WITH LIGHT OPTION 22 SWITCH BRAKE X58 X57 2 1 A gt AL K11 B GRA BLK B GRN YEL COIL 5 TO SP6 GRA 1 SWITCH IGN ST BAT IGN K11 87a RED BLK 30 87 RED YE RELAY SEAT 21 SW SEAT RED BLK 2 l 1 RED YEL RED BLK K12 EB 53m BLK RELAY SEAT Ur 1 pond ORN GRN 53s 959 RED YEL RELAY 5 SEC DELAY ON BREAK SEAT SWITCH OPTIONAL B WITHOUT LIGHT OPTI 12V 22 SWITCH BRAKE X58 X17 ON 5 K11 BLK 2 1 A B B 1 SWITCH IGN ST BAT IGN RED BLK Boe Kt RED BLK 30 87a 87 RED YEL RELAY SEAT S21 SW SEAT RED BLK 2 l 1RED YEL RED BLK K12 mm 53m BLK COIL RELAY SEAT 4 981 ORN GRN 53s RED YEL RELAY 5 SEC DELAY ON BREAK TO 5 Electrical System GRA BLK VIO 7 70 6 o 6 WHT BLK1 COMBINATION GAUGE OPTION b 2 5 GA
14. 3 DERE X59 GRA BLK 18 1 GRA BLU 18 1 17 7 18 1 SANA TBA 2 OPTIONAL F_YEL BLK 18 8 CURB LIGHT 18 1 18 8 BRN 18 1 lt gt P1 HOUR METER VIO BRN 18 1 19 9 YEL GRN 18 1 BLK GRN 18 1 ME gt VIO 18 18 18 2 20 10 BLK 18 1 B VIO 18 18 2 SENSOR GASOLINE X39 X40 4 h 3 J2 2 LIGHT OPTION M 18 2 LIGHT OPTIONS 0 18 19 WHT GRA 18 1 8 1 YEL GRA 18 1 R3 BLUIGEN 14 1 B PUES RED BLK 18 1 9 2 ORN GRA 18 1 YELIVIO 18 1 10 3 BRN WHT 18 1 N PANEL FILTER A YEUBLK 165 TEL TS3 GRN YEL 18 2 1 PINK 18 1 11 4 18 1 GRA BLK 18 1 1 2 209 _ORN BLK 18 1 12 5 GRN YEL 18 1 Ts GRN YEL 18 2 18 6 18 3 14 7 AUN XM ku x55 GBNYEL 18 4 2 SENDER FUEL 2 5 LAMP RIGHT REAR SIGNAL 7 BLUIGRN 14 2 A 5 4 1 BLK 18 9 BLK 18 7 ce B X37 X38 OPTIONAL MOTOR SHAKER 18 7 222 BLKRED 161 gt Pe POCKET FILTER S2 PINKYEL 164 A S MY X125 X126 SWITCH MAIN BROOM ice X71 X73 BLK 18 2 BRN BLK 18 1 15 EES lt lt 18 3 BUE 18 1 18 6 7 1 5 NOTE BRN BLK 18 3 IS FROM MISTING PUMP HARNESS T 53 ikea B ere YELIBLK 16 2 2 BLK 18 18 TROUBLE LAMP n VIO 16 1 GRA YEL 18 1 1m 2 YEL BLK 18 4 C VELBLK 18 11 1 2 7 T y T 1 2 e BLK YEL B
15. 90 25 0009 CONNECTOR LOCKING CAM COVER 2 146 TERMINAL GOLD 1 o YELLOW 18 170456 2 fia 12 PINK DK GREEN 18 1 COIL CYL 2 2 aJJ AMPL 171662 1 TERM okcREEN ORANGE 18 SWS_8100 1429 TERM 172888 2 SEAL DK _GREEN ORANGE 18 PINK DK GREEN 18 OIL PRESSURE SW Green 18 1 7 COIL CYL 4 JUNCTION MUST 3 6 FROM SENSOR CONNECTOR mi errr 1 1 18 2 T 1 xuowzeucK 2112 LT BLUE 18 zea PED_ 12160825 CONN PED_ 12160825 CONN ae EO TOI BR 170454 T 14 18 PED 12089678 SEAL PED 12089678 SEAL e _ _ _ B 3 20 BLACK LT GREEN 18 LI 1 0 5 4 21 DK GREEN ORANGE 18 BLACK LT GREEN 18 5v 22 DK GREEN WHITE 18 LE 23 1T GREEN 18 1 24 AUK ANA PUDS 25 PURPLE WHITE 18 TWIST WIRES TURNS 360 DEG FOOT FULL LENGTH CRANK CRANK 26 WHITE ZPURELE 18 CAM gt 27 GRAY BROWN 18 TWIST WIRES 18 TURNS 360_DEG FOO ur GREEN RED 18 Erie lt gt reram 010006 29 RED WHITE 18 NSC360 D GY FOO YELLOW GRAY 18 P T GREEN PURP 32_LT GREEN BLACK 18 33 RAY DK 35 LT BLUE 18 SPEED 30 RED BLACK 18 599599 36 _YELLOW GRAY 18 ENGINE COOLANT SENSOR GROUND BLACK LT GREEN 18 1 BLA
16. COMMAND A3 IGN SW INPUT CB4 CIRCUIT BREAKER 20 AMP M2 RELAY SHAKER MOTOR SHAKER 87a 1 2 30 87 1 2 CIRCUIT BREAKER 20 AMP RELAY MISTING PUMP OPTIONAL _ 87 M4 1 2 30 87 CIRCUIT BREAKER 10 A OPTIONAL MISTING PUMP 7 OPTIONAL Closed when hopper is down RELAY MISTING PUMP OPTIONAL Closed when filter is plugged SWITCH MISTING PUMP Open when broom is down VALVE 4 DUST CONTROL MISTING SOLENOID VALVE S2 MAIN BROOM A2 CONTROL BOX ASSEMBLY VALVE S8 DUST CONTROL VACUUM MOTOR M i gt 2 0 ie High Pressure LN Steering 6 Flow Spliter N 0 Ez ER Low Pressure 7 z Sump Return Flow Direction Filter Cooler 15 GPM Hopper Up a VAN Sweep Bypass ES o Engine 50 PSI i iR y PSI Y ctum UN OQ EM I Y I Y Sump Y Main Broom Enable Dust Control System S4 1 2 SWITCH HOPPER INTERLOCK qb S5 1 2 18 SWITCH DUST CONTROL FILTER OPTIONAL 52 1 2 A SWITCH MAIN BROOM Side Broom zX Flow Spliter naD 15 1 49672 Main Broom J Dust 42 Service Manual SW8000 Dust Control System Component Locations The diagram below shows component locations for some components rel
17. Check and clean air filter element Check LPG tank setting condition LPG fuel connector LPG fuel LPG fuel connector ee Replace oi x Check gasoline fuel hose and clamp bands Check LPG fuel hose and clamp bands Clean spark plugs sd Clean spark plugs sd plugs Check fuel filter fuel filter Sa fan belt tension and for damage Check battery electrolyte level Replace fuel filter _ Check LPG tank setting condition DEM Check radiator hoses and clamp bands CheckPCVvave PCV valve EE coolant hose of LPG vaporizer Replace airceenersioment Replace gasoline fuel hose clamp bands and fuel filter Clean inside of fuel tank gasoline X fuel Clean water jacket and radiator X interior gt lt gt lt I Service Manual SW8000 Engine System Gasoline LPG 104 Item Service Interval au i B d Every Every Every Every Every Pu 100 hrs 200 hrs 1000 hrs 2000 hrs Year daily weekly Years Replace intake air line Replace breather hose Replace LPG fuel hose and clamp bands ST T ST T T ee Replace coolant hose of LPG oo d eee vaporizer Check LPG vaporizer _ L1 Lo Lo o o ST T ST T ST Replace radiator hoses clamp bands Change radiator coolant Replace battery Change the engine
18. Most control circuits are fairly straight forward with the controller completing the electrical circuits to ground However there are some electrical and hydraulic circuits with interdependencies on other circuits The electric misting pump 1 controlled by a relay from the Main Machine Controller When the mechanical switch 526 1s closed by the operator the misting pump relay coil 1s enabled but waiting for the controller to activate the side broom circuit When the controller sets the side broom output J1 3 to low voltage battery ground it completes the circuit for both the misting pump relay and the side broom hydraulic valve The dust control vacuum motor has two hydraulic interdependencies for it to function If the hopper 1s raised the entire dust control hydraulic circuit 1s bypassed through the S6 valve and none of the dust control or broom circuits will receive hydraulic power When the hopper 1s down the dust control vacuum motor 1 series with the main broom motor It will not receive hydraulic power unless the main broom motor is also active via the 82 Main Broom Enable valve In its relaxed state the S8 hydraulic valve will send fluid through the dust control vacuum motor but when energized the valve will bypass the motor to allow the main broom motor to operate without the vacuum motor operating Service Manual SW8000 Simplified Schematic Diagram BT T BATTERY 12 Vdc CB1 CIRCUIT BREAKER 70 AMP
19. SN 5 S28 x oz B 328 5 A GRA BRN 18 1 ae 2 2 m 5 a x z 2 gt i 5 c B RED 16 3 d d f NC gt 6 3 goes Es E 3 g Ar C RED YEL 18 7 2 5 lt lt E lt gt X151 88 5 gt I CIR BKR 20 AMP X150 SWITCH OIL PRESSURE M7 ACCESSORY CONNECT VIO 143 j X1130 Z Z 2x 5 r Ou una gt gt TO VIO 16 1 VIO CET E2 464 A YYYYYY K7 16 6 AND 14 2 Deen Oa ei T T4 86 85 St d OR Hg x gt gt 87 9 1 87 1 1 ft 3y 5 RELAY ACCESSORY L uL ue DIESEL ONLY _ f E 5 9 n X10 2 SE a Ha 2 2 5 z lt 2 T a ea lt T OX oz Pj j Service Manual SW8000 CAB WIRING Wiring Harness Diagrams p n 56382531 Rev D sheet 3 of 3 Electrical System 74 LP12 STROBE RED BLK OPTIONAL oO e e x E NZ 2 x X191 X190 5 a i M MOTOR ASM WIPER 2 INCLUDES 2 SPEED SWITCH 9 X gt a g X178 203 TP o o ggo VIO GRA 12 3 T eO T T best a 2 BE 525 m lt 153 gt m xxx n lt Htt gt aam 212 T e mi
20. SW8000 Control System 39 Specifications Sample Shop Voltage Measurements Examining signals sent and received at the control board can be very effective 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 Main Machine Controller Sample Voltage Measurements at the J1 Connector Pin V On S valve wel Me 08 peaje valve 0 0 266 qe Using litter control vac valve valve 0 3 13 7 bypass vlv HOPPET OPED On closed Off open valve richer On down Off up or rest valve KeyOm 0 B B B B B B B B B B On raising Off rest or down 0 NE Switched Baty 139 ne BR Nc BR Co EE bU NEN 13 9 12 0 1 20 Bat 001 Service Manual SW8000 Control System Main Machine Controller Sample Voltage Measurements at the J2 Connector Off Comments J2 1 Pedal high NA High voltage reference output of potentiometer 42 2 Pedal wip
21. f Misting Pump 2 Relay Diesel Relay K7 E location K11 Seat Relay Coil and K12 Timer Relay seat switch option only The K11 Seat Relay Coil and K12 Timer Relay are mounted on the front of the frame behind the Hopper and rubber cover K11 Seat Relay Coil Service Manual SW8000 Electrical System 57 22 Brake Switch seat switch option only The S22 Brake Switch 1 located adjacent to the Brake Pedal and is actuated when the parking brake 1 engaged S22 Brake Switch 56 Rotary Sensor The Rotary Sensor is fastened to the mount plate which is mounted to the RTN Bracket Service Manual SW8000 Electrical System 58 Electrical Connectors The following tables list the machine components and their assigned connector or relay and the individual connector pin out assignments The Connector Pin out Assignments tables include connector illustrations to help you identify the various connectors on the machine If you are viewing this document on a computer you can search for the component name or connector ID to find the pin out assignments However if you are viewing a paper copy it will be easier for you to find the correct pin out assignment table for a particular component if you know the connector ID To get the connector ID find the component name from the Wiring Harness Diagram then use the Component to Connector ID Look up Table below to find the corresponding con
22. 12V WITH LIGHT OPTION B 22 SWITCH BRAKE X58 X57 Kt1 2 A 1 A GRA GRA BLK BM TOR GRN YEL COIL RELAY SEAT TO SP6 51 SWITCH IGN ST IGN K11 87a RED BLK 30 87 RED YEL RELAY SEAT S21 SW SEAT RED BLK 2 l 1RED YEL RED BLK K12 5 MI 53m BLK e Li 53s ORN GRN 5 SEC RED YEL TO CB5 RELAY 5 SEC DELAY ON BREAK SEAT SWITCH OPTIONAL WITHOUT LIGHT OPTION 12V B 22 SWITCH BRAKE 58 17 2 1 A GRA GRA BLK B COIL RELAY SEAT 1 SWITCH IGN ST IGN RED BLK ACC SUN RED BLK 30 87 RED YEL RELAY SEAT S21 SW SEAT RED BLK 2 l 1RED YEL RED BLK BLK IN 3 LoF 3s ORN GRN 5 SEC RED YEL TO CB5 RELAY 5 SEC DELAY ON BREAK Service Manual SW8000 Electrical System 54 Component Locations The following components are included in this section e Battery Instrument Panel Assembly Circuit Breakers SPDT Relays K11 Seat Relay Coil and K12 Timer Relay 522 Brake Switch Rotary Sensor Battery The Battery is mounted on the left hand side of the machine frame just behind the left front wheel Service Manual SW8000 Electrical System 55 Instrument Panel Assembly The A2 Main Machine Controller Hour Meter and rter Switch ted are mounte A2 Main on the Panel
23. 35399994599 9 5 9 ww m dq E T 75 ENGING Descr POON 4 44 445 BAGS eee Re aS 75 Manufacturers Technical Literature 76 Engine v gt eee 76 Starter Circuit Description 76 Engine Protection Low Oil Pressure Shutdown 77 Engine Speed CON FOI v ss cR x mE ud NEP Nur dod abd s 77 PIED 78 Component LOcCa oNS gt senri pranada 5 amp Kk 3 3 79 Maintenance and Adjustments oaaae 81 Maintenance Schedule 81 DONEO aeae E UR RR COUR OH 4 1 82 EHOIDeCOGIUNE 5 95 82 Checking ENGNG COON a eee eee P a 82 Replacing Engine Coolant 83 Engine Air Filter MainteDalitE uua woe m dede 84 Replacing tne Fuel Filter ou rtt ELA 84 Bieeding the Fuel es eee 34 85 Tro bleshooti g s zu 4 9 4 39x33 X33 ee REO eee X ROS Ee REE ea 88 General Troubleshooting uou x wow vow wo x HEE HD Pow 88 Engine Overheating lt 89 LOSS OF OU Pressure 89 APECS 3000 Controller Fault Codes
24. INJ CYL 3 INJ CYL 4 BROWN YELLOW 18 PINK DK GREEN 18 SUMITOMO 6195 0043 CONN SUMITOMO 8100 1429 TERMINAL SUMITOMO 7165 118 SEAL INJ CYL 2 BROWN WHITE 18 PINK DK GREEN 18 LT GREEN RED 18 BLACK LT GREEN 18 CRANK SENSOR YAZAKI_ 7223 1324 CONN CAM SENSOR 174352 2 CONN 171662 1 172888 2 SEAL AMP TMAP gt 18 LT GREEN RED 18 BLACK LT GREEN 18 BOSCH THROTTLE PURPLE LT BLUE 18 LT BLUE DK BLUE 18 _1 967616 1 CONNECTOR 965906 5 TERMINAL 967067 1 SEAL OIL PRESSURE SW 172320 2 170454 2 14 18 170456 2 f SUMITOMO 6189 0551 CONN 10 12 MAP GREEN 18 2 guck creen 18 25 PURPLE WHITE 18 TWIST WIRES 10 TURNS 36 DEG FOOT FULL LENGTH BLACK LT GREEN 18 5v CRANK 26 WHITE PURPLE 18 00000 27 GRAY BROWN 18 WIRES 18 TURNS 360 DEG FOO LT GREEN RED 18 G QO A DK GREEN ORANGE 18 B PINK DK GREEN 18 AMP_ 172320 2 178454 2 16 18 170456 2 LABEL 02 HEATED 02 SENSOR PRE CATALYST ALL GOLD BLACK LT GREEN 18 BLACK WHITE 18 D PED 12160825 CONN 12177150 TERM GOLD PED 12160826 LOCK PED 12089678 SEAL ENGINE COOLANT SENSOR BLACK LT GRE
25. SW8000 Component Locations The following components are included in this section Hopper Hopper Lift Cylinder Hopper Door Cylinder Hopper The Hopper is on the front of the machine and holds the dust and debris swept up by the brooms The hopper also houses the dust control system components panel filter panel filter shaker assembly vacuum fan assembly etc Refer to the Dust Control System section for details on the Dust Control System The Hopper Cover lifts up to allow access to the dust control system components Hopper Interlock Switch The Hopper Interlock Switch 54 is a proximity switch that closes when the hopper 1s fully down The switch is mounted on the left side of the machine above the left front wheel This switch must be closed 1n order for the sweeping functions to be enabled Hopper System Hopper Interlock Switch Hopper Prop Rod Hydraulic Manifold Assembly and Solenoid Valves N Hopper Cover Hoper 121 Service Manual SW8000 Hopper Lift Cylinder The Hopper Lift Cylinder is attached to the machine frame and hopper and raises and lowers the hopper Hopper Prop Rod The Prop Rod must be engaged whenever personnel are Hopper working on or underneath the hopper The Prop Rod Lift Cylinder prevents the hopper from being lowered or from dropping down accidentally if there s a failure in the hydraulic system Warning Never wor
26. The glow plugs have an internal resistive element that increases in resistance as it heats up This protects the glow plug from overheating by reducing the current flow as it gets hot Note that you have to hold the key switch in the counterclockwise position to get power to the glow plugs When the power to the glow plugs is switched on the A2 Main Machine Controller will light the glow plug indicator on the control panel for six seconds 78 Service Manual SW8000 Component Locations The following components are included in this section Coolant Temperature Switch Alternator e Starter Air Cleaner Woodward APECS Controller Woodward APECS Actuator Coolant aj emperature Switch e Pressure Switch Alternator f Engine System Diesel Oil Pressure Switch Engine RPM Sensor Fuel Filter ue o 2 79 Service Manual SW8000 Woodward APECS Controller Red Batteny Black White Actuator wnuBlk MARCAS Woodward glue Green dedi 1 AP ECS 5 het si Speed Select 2 Service Yellow Tool Orange Rx Filter Engine System Diesel 80 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 Maintenan
27. be extremely when working around the Binary Pressure Switch Receiver Dryer or other A C components Binary Pressure Switch S34 Refer to Figure 10 MA Note The Binary Pressure Switch is mounted to the top of the A C Receiver Dryer at the rear of et the machine behind the hydraulic oil tank 1 Open the rear Cover Assembly at the back of the cab 2 Remove the electrical connector from the Binary Pressure Switch and check for continuity across the two terminals BA Note The Binary Pressure Switch is normally closed and should have continuity across the et terminals if the A C system is charged adequately and is at normal ambient temperature is continuity across the terminals the Binary Pressure Switch is working correctly Ifthere is very high resistance or no continuity across the terminals replace the Binary Pressure Switch Service Manual SW8000 Options and Accessories 168 Binary Pressure Switch 534 Figure 10 Checking Continuity through the Binary Pressure Switch Service Manual SW8000 Options and Accessories 169 Thermostat S33 Refer to Figure 11 MA 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 con
28. 8 a 21 a lt a o m lt 87 VALVE COMPRESSOR H z t dz 348 du RELAY COMPRESSOR ui ET EEE 8528 a hee am s o M i 207 208 M9 M10 d 85 CONNECT TO L5 CONNECT TO X99 AT L5 333 YEL YEL 34 M8 ri M RED M 1 2 878 UNPLUG X99 FROM 15 85 HOPPER lt j ORN orn V 8 c 87 BLU MV UP DOWN VALVE AND CONNECT IT TBERMOSTAT RELAY CONDENSER FAN MOTOR CONDENSER FAN MOTOR BLOWER MOTOR BLOWER SWITCH PRESSURE AY Nilfisk Advance Service Manual SW8000 75 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 Engine Description The Kubota V1506 diesel is a four cylinder liquid cooled naturally aspirated engine A Bosch
29. DK BLUE YELLOW 18 GRAY RED 18 GRAY DK BLUE 18 PoC RANGE YELLOW 18 uwmuzzrx rommoou PINK DK GREEN 16 12V RELAYED POWER _ 14A666 AA DEUTSCH 0413 204 2005 PLUG TRW 6476883801 CLIP a ALTERNATOR CONN UNUSED SWS_ 6189 0443 CONN 2 PINK DK GREEN 18 SWS 8100 0460 TERM 5_ 7165 0395 SEAL SWS_ 7160 9465 LOCK R3 TAN BLACK 18 2 RED 16 5 gt PINK YELLOW 16 5 PINK TAN 18 1 r 4 FUEL PUMP RELAY CONNECTOR 2 PED 15326868 CONN PED_ 15326269 TERM PED_ 12191153 SEAL PED 15305171 CAVITY PLUG CAP WITH MATING CONNECTOR DIAGNOSTIC CONNECTOR WITH CLIP UNUSED UNUSED tees EPC_1F1T 144624 AA 004 CONN UNUSED 15 0330 930009 TERM 18 20 if required 1 UNUSED CTS 0330 940001 TERM 14 16 if required L p BLUE PINK 18 EPC E6DB 14A468 DA LOCK Electrical System 70 Service Manual SW8000 Electrical System 71 Wiring Diagram Kubota LP Engine p n 56107659 Rev A PINK DK GREEN 18 1 COIL CYL 1 18 2 D CRANK SENSOR LABEL PRE 02 LABEL POST 02 WHITE PURPLE 18 15 YAZAKI_ 7223 1324 CONN HEATED 02 SENSOR HEATED 02 SENSOR POST CATALYST ALL GOLD PRE CATALYST ALL GOLD PURPLE ORANGE 18 2 2 CAM SENSOR 174352 2 CONN BLACK LT GREEN 18 SWS_ 6195 0003 CONN GRAY BROWN 18 1 FIRING ORDER 1 3 4 2 gt gt
30. MAIN BROOM 1 SWITCH MAIN BROOM Side Broom Lift High Pressure Low Pressure Pilot Control Apter piis Sump Return sensuum Flow Direction 3 Side Broom Lift 77 Pilot Controlled E b Check Valve gt 3 Dual Broom N w o Pressure N S N I E Speed w Pressure gt Control I Side Broom To Steering 9 I Flow Spliter I FI li Pressure I Relief Main Broom Enable Hopper Up Sweep Bypass E Service Manual SW8000 Sweep System Side Broom 191 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 1s active and all other prerequisites to that function are also true Hydraulic Circuit Brooms Off When the side brooms are not active the lift cylinders are held in the lifted state and no fluid flows to the motors The hydraulically controlled valve V1 is in the inactive state because 3 is also inactive and no hydraulic pressure 1 present on the control circuit This also sets the pilot controlled check valve C2 inactive so it functions as a normal check valve This check valve keeps the brooms the lifted state even if the hydraulic system 1 shut down Piloted chec
31. Manifold Assembly Broom Cylinder ah Side Broom 2 Hopper Lift Cylinder y Gear Piston Ben Lo S Pump Assembl Reservoir Steering Cylinder Service Manual SW8000 Hydraulic Pumps The engine drives the two hydraulic pumps that power the drive wheel and the various system components The Piston Pump 2 48 CIR is a variable displacement axial piston pump that powers the drive motor The Gear Pump 1 02 CIR powers the main and side broom motors dust control vacuum fan motor hopper lift cylinder hopper door cylinder side broom cylinder steering control unit and steering cylinder The Test Port 1 located on the pressure side of the Gear Pump to allow you to measure the pressure from the Gear Pump To P Port on Hydraulic Manifold Assembly To B Port on Drive Motor Ate Te By Hydraulic Manifold Assembly The Hydraulic Manifold Assembly contains the hydraulic solenoid valves that control the oil flow to the main broom motor side broom motor s dust control motor hopper lift cylinder hopper door cylinder side broom lift cylinder and steering control unit To Side Broom Lift Cylinder To Dust Control Motor From Steering Control Unit From Side Broom Motor From Main Broom Motor From Dust Control Motor Broom Motor To Hopper Lift Cylinder Case Drain To Hydraulic System 128 Charge Circuit from Fil
32. Rotary Sensor The Rotary Sensor referred to as the Drive Pedal Sensor 5K Ohm on the Wiring Diagram 1s a rotary potentiometer that 1s connected to the Lever Weldment As the Lever Weldment rotates to drive the machine forward or backward A the resistance through the Rotary Sensor changes proportionately The machine is programmed so the Rotary Sensor is in its dead band resistance range when the Lever Weldment is in the neutral position The A2 Main Machine Controller must detect the Rotary Sensor in its dead band range before the engine can be started Service Manual SW8000 Seat Switch Circuit Description Electrical System 53 The Seat Switch S21 and 5 sec Delay Relay K12 are installed on Nilfisk machines only and will shut off the engine if the Operator leaves the seat for more than one half second Machines also equipped with the Litter Vac Kit option have a parking Brake Switch S22 and Seat Relay K11 that will bypass the Seat Switch S21 when the parking brake 13 engaged This allows the engine to run to operate the Litter Vac with the Operator off of the seat The seat switch and brake switch circuits work as follows The ignition switch provides positive voltage to terminal 15 on the 5 sec Delay Relay K12 Terminal 53M on the K12 is connected to battery ground When the Operator sits on the seat and closes the Seat Switch S21 this provides positive voltage to terminal T on K12
33. SW8000 Electrical System Wiring Diagrams p n 56382530 Rev D sheet 3 of 3 RED f BATTERY 12 Vdc e LLI 2 X CB1 CIRCUIT BREAKER 70 BLU PINK ES BLU PINK 1 RED GRN 30 87 i 2 RELAY NEUTRAL GLOW M2 2E CLOSED IN NEUTRAL PLUGS CIRCUIT BREAKER 15 GRN RED 2 2 2 l cda E2 E3 HE4 s STARTER Gi a amp 1 1 1 2 5 57 xi RED S 6 n SWITCH IGN PINK B B PINK F yr m T 19 GRN RED Lig LP ALTERNATOR A4 Y 3000 GOVERNOR m 1 ORN GRN 1 L2 PINK PINK A RED RED ACTUATOR gt gt WHT BLK CIRCUIT BREAKER 10 AMP enu T 12117802 CONTROLLER GRAVBLU SPEED SELECT 1 MAGNETIC PICKUP BE MAGNETIC PICKUP GEN SPEED SELECT 2 SERVICE TOOL Tx HEL ORN a Do SERVICE TOOL Rx z cc 28 x140 I NO C DIODE LY 4 NC RED YEL lipa SWITCH OIL PRESSURE DIODE X113 X113 D gt FUEL PUMP lt BER PINK id CONTROLLER TO GAUGE SENDER TEMPERATURE 1 S8 1 SWITCH COOLANT TE
34. When K12 sees voltage at terminal T it energizes and sends the voltage available on terminal 15 through terminal 53s to circuit breaker CB5 then to the engine controller Without this power to the engine controller the engine will not run Note that Ifthe voltage from the Seat Switch S21 to terminal T on K12 1s interrupted for one half second or less K12 will continue to send voltage through terminal 53s to circuit breaker CB5 to allow the engine to continue to run Ifthe voltage from the Seat Switch S21 to terminal T on K12 is interrupted for more than one half second K12 will cut off the voltage to terminal 53s and circuit breaker CB5 to shut off the engine If the machine 1s equipped with the Litter Vac Kit engaging the parking brake will close the Brake Switch 522 On machines equipped with the light option the Brake Switch S22 gets positive voltage from relay K5 On machines not equipped with the light option the Brake Switch S22 gets positive voltage from the ignition switch The closed Brake Switch S22 provides positive voltage to energize the Seat Relay Coil K11 which closes the contacts on the Seat Relay K11 The Seat Relay K11 contacts provide positive voltage to terminal T on K12 bypassing the Seat Switch S21 K12 sends voltage through terminal 53s to circuit breaker CB5 and the engine controller to allow the engine to run with the Operator off of the seat SEAT SWITCH OPTIONAL
35. 30 fill to bottom of screen System fill capacity Engine System Diesel amp Petrol gasoline fuel tank capacity Tires Tire pressure all 3 Engine Sound Level At operators ear LPG Gasoline Petrol At operators ear Diesel Speed and Gradeability Maximum grade angle transport Maximum grade angle sweeping Maximum trailer loading angle all models Travel speed Maximum forward Maximum reverse speed General Information 17 14 ft 3961 1000 Ibs 454kg Max 60 inches 152cm 52 5 inches 134cm 94 ft 8 7m 3 19 x 18 x 30 8 1 x 45 7cm x 76 2cm 14 gal 53L 95 242cm 63 160cm 109 in 277cm 11 gal 41 6L 12 5 gal 47 3L 90 100 PSI 6 2 6 9 bar 9 3 dBA 85 5 dBA 20 11 3 20 11 3 19 4 9 mph 14 5km h 5 5 mph 8 8km h Width minimum Width of machine body at the hopper no side brooms Gross Weight Standard machine without options with 175 lbs operator with standard sweeping brooms and full tank of fuel Service Manual SW8000 General Information 18 Fastener Torque Specifications Size Plated Steel Stainless Steel Totus Specifications unless otherwise specified 270 ft Ib 180 ft Ib 36 in Ib 62 inb 22 ft lb 13 ft lb 44 ft lb 25 70 4 5 Service Manual SW8000 Maintenance Maintenance Schedule General Information Maintenance intervals given are for average operating condit
36. 8100 0460 TERM SWS 7165 0395 SEAL 1 SWS 7160 9465 LOCK SWS_ 6189 0443 CONN LT BLUE PINK 18 2 PINK BLACK 18 85 172320 2 170454 2 is STARTER RELAY 170456 2 10 12 BOSCH THROTTLE PURPLE LT BLUE 18 LT BLUE DK BLUE 18 LT GREEN RED 18 BLACK LT GREEN 18 WHITE 12 5 1 967616 1 CONNECTOR AMP_ 965906 5 TERMINAL STARTER SOLENOID AMP_ 967067 1 SEAL PINK DK GREEN 18 DEPR 174262 2 CONNECTOR 2 3 AMP_ 171662 1 TERMINAL SUF 4 9 _ 174263 7 LOCK 7 GV 172888 2 SEAL 12010996 CONN 12015791 CONN 12089305 MALE 14 16 12124580 TRM FEMALE 14 16 12089040 MALE 18 20 12089188 FEMALE 18 20 5 WHITE 18 H li WHITE 18 CAN TERMINATION WHITE LT BLUE 18 IGNITION PINK DK GREEN 16 RED TAN 16 POWER RELAY Service Manual SW8000 Wiring Harness Diagrams p n 56382531 Rev D WITH LIGHT OPTION AND SEAT SWITCH OPTION GRN YEL 16 2 SWITCH BRAKE X57 X58 S22 A lt A 12 2
37. Diagrams at the end of this chapter Is there voltage at each of the three positive terminals on Fan Switch S30 when the Switch is set to the corresponding fan speed VEL RED and ORN wires 70 gt the Fan ref to bat neg witch Yes Is there continuity in the YEL RED and ORN wires from Fan Switch S30 to No positive terminals on Blower wires Motors M9 and M10 Yes Is there 12V in the BLK wire from negative terminal on Blower Motors M9 and No gt Repair the M10 ref to bat pos wire s Yes Replace Blower Motor M9 and or M10 Service Manual SW8000 Options and Accessories Symptom The Blower Motors run but there 1 no cold air coming out of the Evaporator Heater Unit Uh 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 Check the cartridge on Hydraulic Valve L10 and clean replace as necessary Check replace A C Switch 835 Check replace Thermostat S33 The A C system is overheated Check the Condenser Fan Relay K9 Condenser Fan and associated wiring and replace repair as necessary Check the function of the Compressor Relay K10 and wiring and repair replace as necessary Check the auxiliary pump compressor motor and related hydrau
38. MD type mechanical injection pump fitted with an actuator that physically moves the fuel lever inside the pump The injection pump controls the fuel quantity to maintain the selected RPM or shut the engine off Fuel is stored in a tank under the Operator s seat The tank contains a fuel level sending unit An electric pump supplies low pressure fuel to the diesel injector pump There is a replaceable fuel filter cartridge between the fuel pump and the injector pump The injector pump has s small return line that runs to the closest injector The return circuit is carried from injector to injector where it exits the rear injector and is connected to a hose that returns back to the fuel tank The engine uses glow plugs to aid in starting a cold engine The engine RPM is controlled with the Woodward APECS 3000 Electronic Engine Speed Governing System based on requests from the main machine controller The main machine controller sends signals to the Woodward Governing System controller to request one of two engine speeds based on Operator request pa Note There is a Dead Man Lever on the side of the injector pump that can be used to shut the injection pump fuel down to shut off the engine manually Pe Normal IW Position Shutdown Position Dead Man Cath y s The cooling system consists of a standard radiator and belt driven fan Note that the fan pushes air away from the eng
39. The cable or forward reverse Clean or replace the cable or forward reverse controls controls are damaged or dirty as necessary Specifications size 5 x 8 in Shaft 112 in tapered w key Type manually variable displacement axial piston pump tow valve included Displacement 2 48 CIR max Speed 3600 RPM max Piston Pump shaft Rotation Clockwise as viewed from shaft end Continuous pressure 3000 psi 206 8 bar max Maximum pressure 5000 psi 344 7 bar max Main Loop Relief Valve set at 3000 psi 206 8 bar Nilfisk 7 Advance
40. VIO 1 2 BLK LIGHT STROBE OPTIONAL MOTOR SHAKER 87a RED 11 2 BLU BLK 30 87 BLU GRN WHT 1 M 2 BLK CIRCUIT BREAKER 20 AMP RELAY SHAKER H1 87 v VIO 30 87 WHT YEL 1 2 BLK a RELAY HORN K5 HORN VIO BLK RELAY SIGNAL LIGHTS VIO OPTIONAL T 7 RELAY HVAC VIO CB2 K2 87a OPTIONAL RED 1 52 GRA RED 30 F87 YEL BLK YEL BLK 1 2 BLK CIRCUIT BREAKER 20 AMP RELAY LIGHTS HEAD LIGHT RIGHT S22 YEL BLK 1 2 BLK GRN YEL 1 2 2 GRA HEAD LIGHT LEFT SWITCH BRAKE LP3 VIO YEL BLK 9 WHT BLK OPTIONAL E13 LAMP 7 K5 87a i 25 VIO YEL BLK 2 WHT BLK RED 1 252 ORN 30 787 GRN YEL GRN YEL 2 OPTIONAL _YEL_5 6 RIUT REAR SIGNAL CIRCUIT BREAKER 20 A ETON RELAY SIGNAL LIGHTS SWITCH HAZARD OPTIONAL FLASHER OPTIONAL YEUBLK lt WHT alk OPTIONAL GRA RED oP TIONAL E 26 LAMP RIGHT REAR TAIL BRAKE 1 VIO YEL LP6 M5 YEL 2 gt 73 GRN BLK 99 WHT BLK GRN YEL MS BLK OPTIONAL LEFT FRONT SIGNAL MOTOR ASM WIPER OPTIONAL GEN on 46 INCLUDES 2 SPEED SWITCH OPTIONAL LAMP LEFT REAR SIGNAL YEUBLK 98 GRA RED gt lt WHT BLK a7 OPTIONAL fas LAMP LEFT REAR TAIL BRAKE GRN YEL 1 2 M HS t YEL BLK 1 9 2 BLK MOTOR DEFROSTER FAN OPTIONAL CAB OPTION CURB LAMP PT4 YEL BLK 1 _21 592 PTIONA BLK GRN YEL 21
41. 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 example shown here L Connect a Compressed Air Supply Line to the fitting on the Cooling System Tool Connect the Coolant Supply Line to the Cooling System Tool Make sure the Coolant Valve is closed Insert and hold the Cooling System Tool onto the radiator filler neck then press the Air Switch The compressed air travelling through the Venturi Tube Assembly will pull a vacuum on the cooling system to remove air from the system Once the vacuum reading on the Gauge reaches approximately 25 on the green scale release the Air Switch Note that this also a good opportunity to check for cooling system leaks Continue to hold the Cooling System Tool onto the radiator filler neck and open the Coolant Valve to allow coolant to flow into the radiator Once the pressure on the Gauge reaches approximately 5 on the red scale and the radiator is almost full shut off the Coolant Valve and remove the Cooling System Tool from the radiator filler neck Top off the radiator and overflow tank as necessary Compressed Air Supp
42. and displaying a fault code A flashing LED displays the fault conditions When power is first applied to the Controller the LED will flash just once for one second to indicate that the LED 1s operational If there is more than one fault the LED will flash them all If there are no faults the LED will flash once every reset and from then on indicate the detection of engine speed The controller will attempt to shut the engine down for all faults and will not permit starting after reset with fault 1 5 and 6 Flash unit not calibrated Calibrate the unit Excessive engine speed Check parameter settings wiring case ground linkage and speed sensor Unusually low engine speed Check parameter settings linkage load and engine capacity Protection input shuts down engine Check parameter settings and probable cause for fault Download calibration file and recycle power consult 5 Factory settings lost factory EE APECS unit failed Check wiring shielding and recycle power Consult factory Service Manual SW8000 Engine System Diesel 90 Compression Test Note The photos shown in section are from a similar three cylinder diesel ne 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 SE em aca ectrical Nuts a
43. broom cover panels and the side brooms Maintenance and Adjustments Warning Before performing any maintenance or adjustments make sure the key switch is off and the key is removed from the machine Chock the machine wheels to prevent the machine from moving Troubleshooting Problem Cause Correction The wheels are making The wheel bearings are worn Check the wheel wheel bearings brake excess noise and spindle assembly and replace as assembly are damaged required The brakes are not working correctly The brake linings are worn out Removal and Installation Warning Before performing any maintenance or adjustments make sure the key switch is off and the key is removed from the machine Chock the machine wheels to prevent the machine from moving Never work under a machine without safety stands or blocks to support the machine When jacking the machine do so at the designated Tie Down Jacking Locations To Remove and Reinstall a Wheel The Wheels are held onto the Brake and Spindle Assemblies with 5 lug bolts The Brake and Spindle Assemblies are fastened to the machine frame with 1 2 20 Hex Screws 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 five lug bolts that secure the wheel 4 Repair or replace the wheel assembly Service Manual SW8000 Wheel System Non Traction 197 5
44. comfort throughout a wide Technical Specifications range of ambient temperatures Total Machine Height with Cab Refer to Figure below 79 5 in 202 cm without Amber Strobe Kit 84 5 in 215 cm with Amber Strobe Kit installed System Voltage 12 VDC Heater Temperature Control Electronic Water Valve w Bypass 1 Fasco OEM p n 2807 510 154 Fasco p n DC136 Heating System Blower Motors A C System 1 8 HP 4200 RPM three speed 4 5 Am 2 SPAL type 008 A37 C 42D 4 5 Amp Refrigerant R 134a 1 3 Ibs Condenser Fan Motor SPAL type VA13 AP9 C 35S 6 9 Amp Compressor ICE TM 08 HD 5 cu in 82 0 cc per revolution 700 6000 RPM Compressor Motor Sauer Danfoss p n 121 20 045 00 1 02 cu in 16 7 Heating System Capacity cc displacement 20 000 BT Us hr Air Conditioning System Capacity 13 000 BTUS hr Figure 1 Cab Height Service Manual SW8000 Options and Accessories 152 Cab Controls Refer to Figure 2 Cooling Fan Switch Dome Light Heater A C Fan Switch Heater Temperature Control A C On Off Switch Q oo A Windshield Wiper Switch Figure 2 Cab Controls Service Manual SW8000 Heating System Components Refer to Figure 3 10 11 12 18 14 15 16 Blower Motor Blower Assembly Heater Core Heater Air Box Assembly Filter Coolant Tube From Engine Radi
45. driven by the engine and powers the hydraulic Drive Motor Hydraulic lines A and B connect the Piston Case Pump to the Drive Motor Drain Port The Case Drain Port is connected to the reservoir The Charge Pressure Inlet is connected to the filter When the internal tow valve in the SE Piston Pump is actuated it bypasses R dn Pressure the hydraulic circuit from the Piston 25 Inlet Pump to the Drive Motor to allow the rear drive wheel to rotate freely when towing or pushing the machine Refer to the General Information section for instructions on how to set the tow valve when towing or pushing the machine Service Manual SW8000 Wheel System Traction Foot Pedal Assembly The Foot Pedal pivots the Foot Throttle Plate to move the Lever Weldment Push Pull Control Cable forward and backward The Lever Weldment Push Pull Control Cable actuates the forward reverse controls connected to the piston drive pump Forward Reverse Controls The forward reverse controls connect the Foot Pedal to the drive pump control shaft Pressing the Foot Pedal changes the angle of the swash plate inside of the drive pump T Lever The direction in which the swash plate is moved determines Weldment which port on the drive motor receives the hydraulic oil from Push Pull the piston pump This determines the machine direction e The distance to which the swash plate 1s moved determines the volume o
46. eee 4x x 393 95 9 X 45 eee 3 3 b 54 4 OE 117 Lower 118 Open Hopper Doof 119 dose uus EESXeEAZa3 om EN X 5R4aes 3xaG5943 55259 9 95 120 Component 5 121 g2 x4 3 4 x mx pp 121 Hopper Interlock Switch 121 Hopper Lift 122 HOEF FOD O 6 122 Hopper Door 123 Hydraulic Manifold Assembly and Solenoid 123 Troubleshooting 124 SpecincatlOliS s ax aue ow xe e XL OR D Cw 3 Ue Tw Ue 126 Hydraulic 127 Functional Description 127 BUT Dr 127 PHINDS 128 Hydraulic Manifold Assembly 128 5 129 Electrical Circuit lt 129 Component 5 130 Hydraulic Piston and 5
47. filter may need to be cleaned or X 40 replaced more often if the machine is operated in dusty environments Clean the heater core fins and air box heater only Clean the evaporator and heater core fins inside the evaporator heater unit A C only Clean the condenser fins A C only To Clean and Replace the Cab Filter Refer to Figure 5 1 Remove the four screws holding the Cab Filter Cover then lt remove the Cab Filter Cover and Filter from the machine a 2 Clean the Filter using any of the following methods Tap the Filter gently on a flat surface dirty side down Clean the Filter with compressed air 100 psi blown Filter 6 from the inside cab side of the Filter CN Soak the Filter in warm water for 15 minutes rinse with clean water 40 psi max water pressure then air dry don t use compressed air Make sure the Filter is completely dry before reinstalling 3 Reinstall the Filter and Cab Filter Cover then reinstall and tighten the four screws E a Cab Filter Cover US Figure 5 Cab Filter Service Manual SW8000 Options and Accessories 156 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 the Heater Air Box Assembly The Blower Assembly the Heater Air Box
48. for any mechanical binding or damage to the door mount or hopper door hopper door pivot points hopper door cylinder and cylinder cylinder mounting points Correct as necessary Specifications 1 S5 S6 S7 and 9 Solenoid Valves Nominal Coil Resistance 8 Ohms Bore Diameter 2 5 in Hopper Lift Cylinder Hod Diameter 1 25 in Bore Diameter 1 5 in Hopper Door Cylinder Rod Diameter 75 in Nilfisk s Advance Service Manual SW8000 127 Hydraulic System Functional Description Overview The hydraulic Piston Pump powers the traction Drive Motor The hydraulic Gear Pump powers the Main Broom Motor Side Broom Motor s and the Dust Control Vacuum Fan Motor The Gear Pump also powers the Hopper Lift Hopper Door and Side Broom Cylinders and the Steering Control Unit and Steering Cylinder The Piston Pump and traction Drive Motor are a closed system Electrically controlled solenoid valves located in the Hydraulic Manifold Assembly direct the hydraulic oil from the Gear Pump to the various system components to perform the sweeping and dust control functions raise and lower the hopper and open and close the hopper door The hydraulic oil from the machine system components returns through the Oil Cooler and Oil Filter to the Reservoir MA Note The individual hydraulic motors and cylinders are described in the corresponding machine et y system sections Hopper Door Cylinder Hydraulic
49. hopper door cylinder Note that The 4 solenoid valve is only installed on machines equipped with the Litter Vac Kit On machines without the Litter Vac Kit a captive plug is installed in the S4 location 1n the Hydraulic Manifold Assembly 5 Hopper Up Down 54 Only Installed on Models with a _ Litter Vac Kit M To Upper Port on Port on Hopper Lift Cylinder 2 Hydraulic Manifold Assembly Hopper Door Cylinder Hopper System 113 Hydraulic Manifold Assembly C To Upper Port on Hopper Door Cylinder N To Lower Port on Hopper Lift Cylinder Service Manual SW8000 Hopper System 114 Hopper System Wiring Diagram Battery 12 VDC 2 CB1 Circuit Breaker 70 Amp 2 d m 2 o CB4 Circuit Breaker 20 Amp GRN BLU 1 2 vio VIO A2 Main Machine Controller BLU WHT Valve 1 Hopper Close Open L5 RED GRA Valve S5 Hopper Up Down Closed when Hopper is Down BLU GRA REDBLK 1 54 2 BLK Valve S6 Hopper Up Bypass 5 Interlock L7 Switch BLK WHT Valve S7 Hopper Open L9 YEL GRN Valve S9 Hopper Lower Touch Pad Switches Hopper Door Open TPS8 1 4 9 Hopper Up TPS9 1 4 9 Hopper Down TPS10 2 1 Hopper Door Close Common Ground Service Manual SW8000 Hopper System 115 Hopper System Circuit Description Positive voltage is provided to hopp
50. in the chassis to allow the Hopper to swing up and down The Hopper Lift Cylinder is attached to the Hopper Lift Arm Weldment and chassis and extends and retracts to raise and lower the Hopper The mechanical Prop Rod can be engaged to prevent the Hopper from being lowered or from dropping accidentally if there s a problem with the hydraulic system Hopper Lift Arm Weldment Service Manual SW8000 Hopper Door The Hopper Door is attached to the Hopper Door Pivot The Hopper Door Pivot is mounted to the two Side Broom Arm Brackets to allow the Hopper Door to open and close The Hopper Door Cylinder is attached to the Hopper Door and hopper lift arm weldment and extends and retracts to open and close the Hopper Door Hopper System 112 Service Manual SW8000 Hopper Hydraulic System The hydraulic solenoid valves that control the Hopper Lift Cylinder and Hopper Door Cylinder are in the Hydraulic Manifold Assembly The solenoid valves are electrically energized by pressing the corresponding switches on the control panel The hopper lift cylinder is connected to ports M and N on the Hydraulic Manifold Assembly The S5 Hopper Up Down S6 Hopper Up Bypass and the 9 Hopper Lower solenoid valves control the hopper lift cylinder The hopper door cylinder 1 connected to ports and C on the Hydraulic Manifold Assembly The S1 Hopper Close Open and S7 Hopper Open solenoid valves control the
51. is started Service Manual SW8000 Hydraulic Diagrams Drive Motor in Neutral When the foot pedal is 1n the neutral position with the engine running the Piston Pump will not send any oil to the Drive Motor Tow Valve in Bypass Position If the Drive Motor is mechanically rotated by towing or pushing the machine it acts as a pump Since there 1s no place for the hydraulic oil to flow the wheel may not turn at all and may skid across the floor if the machine 1s towed or pushed with great enough force The machine 1s equipped with a Tow Valve to eliminate this problem when towing or pushing the machine When the Tow Valve is rotated to the bypass open position the oil 1s free to flow to and from the Drive Motor through the Tow Valve when the rear wheel 1s rotated bypassing the Piston Pump Refer to the General Information Towing or Pushing the Machine subsection 1n this manual Note that while only one drive wheel direction 1 shown in the adjacent drawing the Tow Valve functions the same when the drive wheel is moved in either forward or reverse Wheel System Traction 201 Y From Oil Cooler and Filter Reservoir From Oil Cooler and Filter Reservoir Service Manual SW8000 Drive Motor in Forward or Reverse When the engine 1s running and the foot pedal 1s moved to either the forward or reverse position the Piston Pump sends oil to the Drive Motor to drive the machine
52. l the hopper interlock No Inspect the motor Yes Replace the brush or D hub and broom motor as necessary collar for damage No Do the side brooms Y S Replace the main Done function as expected broom motor No volts at the main poe Done broom solenoid Check for 12 volts at the ves Repair wiring between main controller between controller and solenoid Done pins J1 11 and J1 6 NO Check the operation of the Broom Down sensor J2 12 should show 12 volts to ground when the broom is down Troubleshoot the controller and the controller inputs Service Manual SW8000 Sweep System Main Broom 189 Specifications Solenoid Coil Resistance Values 10 21816946101 Normal Resistance Value S6 Coil Nilfisk s Advance Service Manual SW8000 190 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 Circuit Overview BT BATTERY 12 Vdc A3 ENGINE SYSTEM A2 CONTROL BOX Closed when hopper is down i 54 SWITCH HOPPER INTERLOCK Closed when filter is plugged 55 SWITCH DUST CONTROL FILTER Open when broom is down S2 VALVE S2
53. loose dust from the filter Then soak the filter in warm water for 15 minutes then rinse it under a gentle stream of water maximum pressure 40 psi Let the filter dry completely before putting it back into the machine Follow the instructions in reverse order to install the filter If the gasket on the filter is torn or missing it must be replaced NOTE Before replacing filter clear debris from dust plate located under filter Verify that the debris flap at the rear of the dust plate swings freely Service Manual SW8000 General Information 24 SW8000 PM Checklist Defect Codes Customer A Needs Adjustment B Binding Address C Dirty or Contaminated D Damaged Bent or Torn City ot Zip L Leaks M Missing Model Serial Hours W Worn Out Defect Codes Does Not OPERATIONAL INSPECTION ITEMS circle Work Check Neutral Safety Sense Switch operation To test depress drive pedal and start the engine it should not start 2 Engine Starting with pedal in neutral if it will not start check sensor Starts Hard switch programming 3 Engine Speeds 4 GIP 12002400 RPM 4 Engine Speeds Diesel rote electrical actuator inkage 1200 2400RPM 5 Drive Pedal Linkage check for FWDIREV arive and any neuat creep e Drive System so 7 Brakes check botn service aparin ExssvePay S Hopper Up Down also ch
54. lt 30 uus acd bu EEG 30 Mam Migenne Controller 33 Component 5 s s ses rs EROR RO NOROUR ON m 3e 3 m 80 2 5 34 Main Machine Controller 35 Hydrostatic Neutral Position and 35 Recall of Stored Fault Codes 35 Automatic 5 s amp sax oom xx RR X E UE XX x E 36 Troubleshooting 36 Service Manual SW8000 Main Controller Error 36 Removal and lt 38 38 39 Sample Shop Voltage 39 Dust Control System 24 ue x OE Pour See eae QE XE 41 Functional lt 41 DustGuard Spray System 41 Dust Control Vacuum SYSTEM ioe ce bbw eRe XOE BG MERRY REESE YE 4 Eo po x 41 CCU s s 459 9 9 6204 5
55. lt 5 201 Dive Motorin Neural S vv meu E OE ROBO eR E ROO eas 201 Tow Valve Bypass 5 201 Drive Motor in Forward or Reverse 202 Drive Motor Stalling 203 Component 204 Piston drive Pump Tow Valve 204 Drive Motor and Rear Wheel Assembly 0 eei 204 Foot Pedal Assembly 205 Forward Reverse 205 vii Service Manual SW8000 viii s sa 2 3 3 9 5 5 52555339533 206 To Set the Drive Pump Neutral 206 207 SOCEINCIUNONG E s ss sss srera 3 x 4 40 9 EP 4 207 Service Manual SW8000 General Information General Machine Description The SW8000 machine 1s 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 br
56. m GRN 18 1 2 1 BLK SQ WHT L8 n 4 I SP14 VALVE S8 DUST CONTORL BYPASS Hi NUN LAMP LEFT FRONT SIGNAL X102 x 2 PINK 16 4 OPTIONAL 1 22 2 18 1 m 16 3 2 1 PINK 16 7 X61 X62 X63 X64 23 LP11 X43 LP2 1 1 VIO 1843 172 pe 44 zi 5 4 YELBLK 18 1 A YEUBLK 18 13 A 1 7 2 LF BLK 18 11 B B 20H L9 a X46 X45 x BLK 18 17 28 BLK 18 36 gle YELBLK 18 10 A gg A VALVE S9 HOPPER LOWER 3 Vi0 18 17 g A sp 2489 LAMP WORK 103 d SSS es HEAD LIGHT LEFT 1 122 2 YEL GRN 18 1 z 35 2222 1 1 VIO 18 23 a D UM g O5 LPS OPTIONAL ES z D DT REAR SIGNAL X50 shale d F1 D SP19 A A RED BLK 18 1 aee 2 RED 18 2 18 1 z BLK ON WET FUSE 1 2 x d 2 1 BKS o Bo B BUCO ooo x a RI X72 X74 gt gt gt T S 18 3 GRN 18 4 4 2 Bi m BLK1 1 gt 2 f SWITCH HOPPER INTERLOCK abe EA RED T 1 2 BLK 18 15 B BLK 18 35 SP20 2 X165 12 YEL BLK 18 3 C C YELBLK 18 12 2 amp gi WHT 1 SP3 X167 SENDER OIL PRESSURE GRA 18 2 D c D GRA 18 5 _2__1_RED lt OPTIONAL SP21 LP13 LAMP LEFT REAR TAIL BRAKE OPTIONAL BLK ORN 18 2 Notes 1 Reference 56382530 Wiring Diagrams Electrical System 72 Service Manual SW8000 Electrical System 73 Wiring Harness Diagrams p n 56382531 Rev D sheet 2 of 3
57. machine Do not dispense fl ammable cleaning agents operate the machine on or near these agents or operate in areas where fl ammable liquids exist Only use the brushes provided with the appliance or those specifi ed in the instruction manual The use of other brushes may impair safety Do not use the machine without a falling object protective structure FOPS in areas where it is likely that the operator is hit by falling objects Machines shall be parked safely The machine shall be inspected by a qualifi ed person regularly in particular regarding the LPG container and their connections as required for safe operation by regional or national regulations Observe the Gross Vehicle Weight GVW of the machine when loading driving lifting or supporting the machine This machine is not approved for use on public paths or roads This machine is only approved for hard surface use This machine is not suitable for picking up hazardous dust When operating this machine ensure that third parties particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the key switch off removing the key and applying the parking brake Service Manual SW8000 General Information 12 Turn the key switch off and remove the key before changing the brooms and before opening any access panels Take
58. on the red scale and the radiator is almost full shut off the Coolant Valve and remove the Cooling System Tool from the radiator filler neck Top off the radiator and overflow tank as necessary Compressed Air Supply Line m a P ar mm 3 yt _ iz B 3 1 80 Amr gt i Air Switch Venturi Tube Assembly Filling Cooling System with Coolant Coolant Valve closed Coolant Supply Line Service Manual SW8000 Engine System Gasoline LPG 106 Engine Air Filter Maintenance Caution When servicing the engine air filter elements use extreme to prevent loose dust from entering the engine Dust can severely damage the engine Service the air cleaner more frequently under severe dusty or dirty conditions 1 Remove the air cleaner elements from the air cleaner assembly and inspect them for foreign material restrictions or signs of excessive wear or damage Replace the elements if necessary 2 Remove all dust and foreign matter from the air cleaner housing 3 Reinstall the air cleaner elements 4 Reinstall the air cleaner cup then securely fasten the retaining clips Troubleshooting The EControls engine management package supports robust self diagnostics and is capable of setting scores of Diagnostic Trouble Codes DTCs DTCs and sensor data can be viewed on a coputer using the GCP Display software along w
59. or the A C compressor motor Compressor Relay K10 Refer to Figure 9 2 Note The Compressor Relay is located in the engine compartment below the main broom lever 1 Make sure the hopper is down then switch on the 2 Back probe the BLU BRN wire connected to the Compressor Relay If you see 12 VDC at the BLU BRN wire referenced to battery negative the Compressor Relay is working correctly If you don t see 12 VDC at the BLU BRN wire proceed to step below 3 Remove the electrical connector from the Compressor Relay and check for continuity across the load terminals 80 and 87a BA Note The Compressor Relay is a normally closed relay and should have continuity across the load en terminals with the electrical connector removed is continuity across load terminals 30 and 87a the Compressor Relay is working correctly Check the connections and wiring upstream of the Compressor Relay and repair replace as necessary If there is very high resistance or no continuity across terminals 30 and 87a replace the Compressor Relay Service Manual SW8000 Options and Accessories Compressor Relay K10 0 E s Y 4 Figure 9 Compressor Relay hot after operation and can cause severe burns Always use the appropriate precautions Warning High pressure side air conditioning components fittings lines and hoses
60. output remains low Service Manual SW8000 Component Locations Engine System Gasoline LPG 98 LPG And Gasoline Engine Common Electrical Components The following components are included in this section Most photos are of LPG Engine Alternator Electronic Throttle Body Cam Position Sensor Connector 1 Connector 2 Crank Position Sensor Diagnostic Connector Engine Control Module Engine Coolant Sensor Ground Figure 1 LPG Engine Shown Left Side Connector 1 and Connector 2 Ignition Coils Knock Sensor Oil Pressure Switch Post Catalyst O Sensor Power Relay Inside Engine Fuse Relay Box Pre Catalyst O Sensor Starter Starter Relay Inside Engine Fuse Relay Box TMAP Sensor E Electronic Throttle Body m Service Manual SW8000 Oil Pressure Switch Figure 2 LPG Engine Shown Left Side Diagnostic TM AP Connector Sensor Engine Fuse Relay Box 5 5 2 O E j E y 2 4 Figure 3 LPG Engine Shown i A AND Engine System Gasoline LPG 99 Service Manual SW8000 Engine System Gasoline LPG 100 4 7 NN Engine Coolant Sensor gt Figure 4 LPG Engine Shown Figure 5 LPG Engine Shown Rear Under Air Cleaner Cam Position Sensor P
61. storage 3 Move the machine to an indoor storage area 4 Shut down the engine according to the shut down procedures 5 Make sure the Ignition Switch is OFF and the Parking Brake 1 engaged Note It is safe to clean this machine with a pressure washer as long as you do not spray directly at or into electrical components at the radiator or hydraulic oil cooler The machine should always be allowed to dry completely before each use 19 Service Manual SW8000 General Information 20 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 Runthe 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 Note The 4 cylinder LPG engine will continue to run for few seconds after switching the key to off This is part of the proper operation of the closed loop electronic control system 6 Apply the Parking Brake Important Machine Lubrication Rear Steering Yoke Bearing Assembly Once every 150 hours attach a grease gun to the yoke bearing pivot zerk location un
62. the Control System Main Machine Controller Programming Hydrostatic Neutral Position and Dead band section 2 Check the relay coil resistance If not 85 5 ohms replace the relay Check the wiring to the starter and repair as necessary The engine cranks but No power to the glow plugs Check wiring from the ignition switch to the glow will not start plugs and repair as necessary Check the ground connection to the glow plugs and repair as necessary No output from the APECS Check wiring to the Controller and repair as 3000 Controller to the necessary actuator Check the wiring from the actuator terminals on the Controller to the actuator and repair as necessary The APECS 3000 Controller is Check the APECS 3000 Controller fault codes and not operating correctly take the recommended corrective actions Refer to the APECS 3000 Controller Fault Codes subsection The engine stops The coolant temperature is too Refer to the Engine Overheating Problems section running service high below indicator light is on The oil pressure has Refer to the Loss of Oil Pressure Protection section dropped below the minimum below acceptable pressure Engine will not runat There is no 12V signal from Check the wiring from pin J1 17 to the Speed Select operating speed pin J1 17 on the A2 Main 1 terminal on the APECS 3000 Controller GRA BLU Machine Controller to the wire Speed Select 1 terminal on e f this doesn t correct the pro
63. 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 1s in neutral which would prevent the sweeping system to engage Correctly setting these adjustments 1s important because they control when the machine can be started and also when sweeping functions activate and deactivate These adjustments should be made anytime the Main Machine controller or potentiometer are replaced the mechanical adjustment 1 performed or any time the machine shows symptoms of misadjustment 1 Make sure the keyswitch is in the off position 2 ensure the drive is in the mechanical neutral position press the drive pedal into reverse and slowly release 1t Avoid biasing the neutral position and do not move the pedal for the remainder of the procedure 3 While holding the Engine Speed switch turn the keyswitch to the on position Continue to hold the speed switch until all display indicators turn off approximately 2 seconds 4 When the Engine Speed switch is released the controller will record the resistance value fr
64. 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 To remove the hopper dust control filter 2 uuu the Hopper Dust Control Filter out of the machine Unlatch and open the Hopper Cover Make sure that the Hopper Cover Prop Rod 1s in place Inspect the top of the Hopper Dust Control Filter for damage A large amount of dust on top of the filter is usually caused by a hole in the filter or a damaged filter gasket Inspect the bottom of the Hopper Dust Control Filter If the filter 1 covered with wet dry mud the dust control system will not function properly without replacing or thoroughly cleaning the filter using Method Loosen the four Shaker Assembly Retainer Knobs Lift off the Dust Filter Shaker Assembly to access the panel filter Note Be careful not to damage the shaker motor wiring Clean the filter using one of the methods below Method A Vacuum loose dust from the filter Then gently tap the filter against a flat surface with the dirty side down to remove loose dust and dirt 2 Note Take not to damage the metal lip which extends past the gasket Method B Vacuum loose dust from the filter Then blow compressed air maximum pressure 100 psi into the clean side of the filter in the opposite direction of the airflow Method C Vacuum
65. the floor 5 Raise the broom release the parking brake and move the machine so that the polished strip 1s visible 6 Inspect the polished strip on the floor The target width is between 2 and 3 inches 50 to 80 mm Ifthe strip is less than 2 inches 50 mm wide lower the broom by loosening the knob 4 and sliding it forward Ifthe strip is more than inches 80 mm wide raise the broom by loosening the knob 4 and sliding it back towards you 7 Repeat the procedure to verify the settings Inspect Housing Skirts Visually inspect the skirts when rotating or replacing the main broom The skirts should be replaced or adjusted if they are torn or more than 1 4 inch 6 35 mm above the floor Service Manual SW8000 Sweep System Main Broom 188 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 52 must be open and the hopper interlock switch S4 must be closed for the main broom system to run Main broom motor will not run Inspect the S6 Bypass valve Can the hopper be No solenoid and wiring If this solenoid No Troubleshoot the main raised and lowered is not active no downstream machine controller hydraulics will function Yes Yes Verify that the hopper is gt down and troubleshoot
66. to the DEPR and Mixer Assembly Service Manual SW8000 Engine System Gasoline LPG 96 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 MA 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 Engine Starter Circuit Description The starter is prevented from engaging whenever the drive pedal is NOT in the neutral position A Neutral relay K4 is in series between the key switch and the starter solenoid When the relay is at rest not energized current is allowed to flow through the normally closed contacts 80 to 87a on to the starter The Main Machine Controller monitors the Drive Pedal Sensor to understand the cur
67. to the actuator which then moves the fuel control lever to regulate the engine speed The Controller increases the current it sends through the actuator to increase the engine speed The actuator 1s spring loaded in the no fuel default position and will shut off the fuel to the engine when there 1s no electrical current available from the Controller When the A2 Main Machine Controller receives an engine speed request from the engine speed switch on the control panel it sends either 12V or OV from pin J1 17 to the Speed Select 1 terminal on the Controller The Controller then sends the appropriate current from the Actuator terminals to the actuator to obtain the desired RPM corresponding to the engine speed requested The following table shows the inputs to the Speed Select 1 and 2 terminals and the resulting action APECS 300 Controller Inputs Speed Select 1 Speed Select 2 Engine Condition High Speed Not Used Low Oil Pressure Shutdown Service Manual SW8000 Engine System Diesel Glow Plug Control Battery 12 VDC T 2 1 Circuit Breaker e iD 70 Amp 1 2 2 2 2 T1 GRN RED E Bi 122 p 1E4 d 2 dH Starter E 19 GRN RED Dp HD 1 1 1 1 S7 m B Ignition fe Switch O lt The engine is equipped with glow plugs to assist starting cold engine The Battery provides voltage to the Glow Plugs when the Ignition Switch S7 is in the engine run position
68. 0 10 4 41 Simplified Schematic 42 Component LOCANONS s s s We Ak RHEE OSS 43 Maintenance and 44 Dustguard Spray Nozzle 44 Dust Control Filter Cleaning 44 Troubleshooting seen Ge bw 45 Dust Control Vacuum Motor will not Run 45 Dust Control Vacuum Motor will not Shut Off 6 0 a 46 Shaker Motor will not RUN oss EON tbe ee 47 Misting Pump will not 48 5 49 Electrical 50 Functional Description 50 CVETVIEW os 9 4 9 9 9 XP NOR Sow d XE NERA M UE UP A NOE eH ee SR 50 Panel Assembly 5 du wu uec 244 d 50 Circuit Breaker lt 51 Wire 52 OR S RR OR RURSUS BU S X PIE NUAGES PS dud 4 52 Sear Switch Circuit DescHDHOl se d SORGE 50 53 Component 5
69. 1 1 1 1 1 1 1 1 Dust i 1 1 1 1 1 1 1 1 Low Pressure T S Y Steerin GPM FI lit N Sump Return 9 ow Spliter hi ae ee Flow Direction 9 Enable Pressure Relief Filter Cooler 15 GPM Hopper Up lt Sweep Bypass Ep ww Engine 50 PSI E 1 02 Oa a ce y PSI 183 Service Manual SW8000 Sweep System Main Broom 184 Hydraulic Operation The hydraulic system 1s 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 The Bypass solenoid valve 56 is normally open meaning that fluid flows through it when the solenoid is not active This provides a low resistance path for hydraulic fluid back to the reservoir when no downstream hydraulics are being used This solenoid valve is active fluid flow blocked any time the main hydraulics related to the sweeping system are required This includes raising the hopper or any of the broom and dust control hydraulics If this valve fails to energize block flow then the sweep system will either not function at all or function very slowly There are two flow splitters in the system The 2 0 8 6 gpm splitter requires 2 0 gpm minimum to flow to the steering system as a priority and up to 8 6 gpm flow to the rest of the sweep system T
70. 123 Service Manual SW8000 Troubleshooting Problem Correction The hopper doesn t rise when the Raise Hopper Switch is pressed The engine is at idle speed The Raise Hopper Switch is not making connection with the A2 Main Machine Controller There is no power to the S5 Hopper Up Down solenoid valve The S5 Hopper Up Down solenoid valve is not operating There is no power to the S6 Hopper Up Bypass solenoid valve The S6 Hopper Up Bypass solenoid valve is not operating The S9 Hopper Lower solenoid valve is stuck open The S2 Main Broom solenoid valve is stuck open The hopper mount or hopper lift cylinder is binding Hopper System 124 Switch the engine to high speed Check the connection between the touch pad switch panel and pin J3 6 on the A2 Main Machine Controller If the connection is OK there may be a problem with the touch pad switch panel or the A2 Main Machine Controller Check the wiring to the 5 Hopper Up Down solenoid valve The solenoid receives positive battery voltage and is grounded to the A2 Main Machine Controller when the Raise Hopper Switch is pressed Repair replace the wiring as necessary Check the solenoid coil resistance If the resistance doesn t measure approximately 9 ohms 10 replace the coil e Check the function of the solenoid valve cartridge Replace as necessary Check the wiring to the 56 Hopper Up Bypass solenoid valve The solen
71. 130 Hydraulic Manifold Assembly 130 Hydraulic Oil Reservoif o moo RR E RO 131 131 132 Maintenance and Adjustments ees 132 To Check the Hydraulic 1 132 To Change the Hydraulic 133 To Clean the Hydraulic Oil Cooler 133 Troubleshooting oaoa 134 General Troublesh o ng eae re dtd WR eee ee Pe ae Eee 4 134 General Information Regarding Checking Hydraulic Pressures 134 Checking the Gear Pump 135 Checking the Piston Pump 135 um ZEE WB 136 Sees NR NT 27 137 General Specifications ccu eo 137 Service Manual SW8000 Hydraulic Manifold Assembly 138 Special TOOLS x x 3 9 2x45 ESOEG Am RECS OW d m WE des 139 Hydraulic Schematic 56507055 140 Options and 141 SW8000 Deluxe Cab 5 151 Technical 5 1
72. 2 kite GRA BLK 18 1 RED YEL 18 2 18 6 B 2B P3 RED BLK 18 3 GRN 18 1 dud WITHOUT LIGHT OPTION 18 1 OPTION RED BLK 18 2 WITH SEAT SWITCH OPTION GAN 18 2 6 REPLACES P1 AND P2 X12 X13 21 VIO YEL 18 2 BLK 18 38 RED YEL 18 1 A RED YEL 18 3 18 2 Ld 15 WM 53M BLK 18 39 3 1 BLK18 19 E RED BLK 18 4 B RED BLK 18 6 ho 5 18 12 lt veies 26 SWITCH MISTING PUMP 3 ls E H 58S ORN GRN 16 1 BLK 18 13 SW SEAT YEL 16 3 Aa d VELIBLK 16 5 X109 X110 BLK 18 24 5 1 6 YEL BLK 18 11 RELAY 5 SEC DELAY ON BREAK GRN BLK 16 1 ST YEL 16 2 5 TANHES lt SEAT SWITCH OPTION YEL 16 1 a WHEELS GRN 18 2 55 RED 10 1 VOWEL 182 ME 2 1 WHT GRA 18 1 RED BLK 18 3 2 RED BLK 18 4 1 VIO YEL 18 3 9 11 REDBLK 185 ET Acc SWITCH IGNITION GANYEL 18 3 SWITCH DUST CONTROL FILTER YEL BLK 16 5 N OPTIONAL Kt T YEU BLK 16 1 CONTROLBOX ASSEMBLY 14 2 gt zi BLK 14 1 i S Bm 87 RED YEL 18 2 LP9 VIO 18 2 J1 VIO 18 18 VIO 18 3 11 1 BLUWHT 18 1 S6 RELAY SEAT gt 12 2 GRN GRA 18 1 2 22 YEL BLK 18 8 13 3 BRN BLK 18 1 11272 YEL VIO 18 1 SEA BSWITCH OPTION YEL RED 18 1 14 4 BRN YEL 18 1 X79 A5 4 LAMP CURB BLK 18 9 GAUGE FUEL WHT GRN 18 1 4 OPTIONAL NIE GRN BRN 18 1 15 5 RED GRA 18 1 4 SUD HOBBER TEN YEL WHT 18 1 16 6 BLU GRA 18 1 GRN RED 18 1
73. 5 APECS 3000 x1 Controller 2 PINK A RED RED B B BLK Circuit Breaker 10 Amp Connect to Pin J1 17 x2 Machine Controller Actuator WHT VIO s peed Select 1 Actuator WHT BLK Speed Select 2 Magnetic BLU Pickup Magnetic GRN Pickup RED Oil Pressure DIODE Switch S28 X113 X113 GRA BRN D Power to Fuel Pump BLK Da The fuel pump electrical power comes from the NO contact of the Oil Pressure Switch S28 When oil pressure builds the Oil Pressure Switch connects C to the NO terminal to provide power to the fuel pump f oil pressure is lost the Oil Pressure Switch will connect C to the NC terminal This takes power away from the fuel pump and gives 12V to both Speed Select 1 and Speed Select 2 which is the lost oil pressure signal to the APECS 3000 Controller When the APECS 3000 Controller sees this signal 1 shuts down the engine by turning off the fuel actuator on the engine Engine Speed Control The APECS 3000 Controller manages the engine RPM through the use of an electronic actuator connected to the fuel control lever inside the injector pump The Controller monitors the actual engine RPM via a speed sensor connected to the Magnetic Pickup and terminals The speed sensor reads the flywheel ring gear teeth and the Controller compares the actual engine speed to the desired speed setting The Controller sends out a pulse width modulated signal
74. 50 8000 Service Manual Advance Model Numbers 56107501 56107503 56107505 56107507 56107509 56107511 QNilfisk Advance 65 Gasoline 56107512 65 LPG 56107513 65 Diesel 56107514 65 Gasoline w cab 56107515 65 LPG w cab 56107517 65 Diesel w cab trusted since 1906 Nilfisk Model Numbers 165 cm LPG 165 cm Diesel 165 cm LPG w cab 165 cm Diesel w cab 165 cm Petrol English 1 13 Form No 56043163 Service Manual SW8000 Contents General 9 General Machine 9 Service Manual Purpose Application 9 Other Reference Manuals and Information 9 Nilfisk Advance 5 9 Engine Manufacturers Technical 9 9 eee ee 9 Parts ANG Service oaa 10 Name Plate us xx ROROEOR S3 4 3 5 X x 3 R3 P EES ees 10 General Safety 5 5 11 Hopper Safety 12 Jacking The 13 Transporting The 14 Towing Or Pushing A Disabled Mach
75. Assembly Machine e Note that Gas and Diesel Controller 26 Level Gauge mounted on the Panel Assembly adjacent to the Hour Meter models also have a Fuel LI Panel Ss Assembly Circuit Breakers The machine Circuit Breakers are mounted on the Circuit Breaker Panel located below the instrument panel hopper switches i Circuit Breaker Note that additional Circuit typical Breakers are installed on machines i equipped with the optional DustGuard system optional signal lights and the cab HVAC p option ANN Taal ACHING ATTENTION ATTENTO Circuit Breaker et ie e Panel erg it Propane GVW XO LP Pike chine maira Service Manual SW8000 SPDT Relays The SPDT single pole double throw Relays are mounted on the back of the Circuit Breaker Panel located below the instrument panel hopper switches Note that diesel models have an additional SPDT Relay Additional SPDT Relays are also installed on machines equipped with the optional DustGuard system optional signal lights and the cab HVAC option location Electrical System 56 pp Circuit a gt bs i 2r f pre typical Lights CSS Relay K2 P JN 4 Shaker Circuit 27 gt Breaker Panel Neutral a PES iis 4 gi KS 1 a 5 location
76. 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 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 20 circuit breaker CB9 must be closed to provide voltage RED VIO wire to the input load side of the HVAC Relay K8 HVAC Relay K8 must be closed to provide 12 VDC VIO GRAY wire to the positive terminal on the Fan Switch S30 The Fan Switch 30 must be set to the Low YEL wire Medium RED wire or High ORN wire position to provide 12 VDC to the corresponding terminal on the Blower Motor M6 Negative Voltage The Blower Motor M6 must be connected to battery negative BLK wire The control side coil of the HVAC Relay K8 must be connected to battery negative BLK wire Heater Temperature Control The following conditions must be met for the heater te
77. CONDENSOR FAN M ul RR xi DIESEL AND GAS ONLY STARTER B PINKYEL DS D PINKYEL M 2 FUEL PUMP OUTPUT X CB1 BLK RED C C BLK RED CIRCUIT BREAKER 70 K xi T 87 BLU PINK BLU PINK i WES GR lt STARTER COMMAND 2 RELAY NEUTRAL A3 MIL OUTPUT xi CHECK ENGINE LIGHT CLOSED IN NEUTRAL SWITCHED GRN YEL G G GRN YEL OUTPUT TO CONTROL CB3 GRN YEL A CIRCUIT BREAKER 15 AMP ENGINE SYSTEM GROUND BOX ASSEMBLY REFERENCE xi JUMPER INSTALLED BETWEEN 15 TO 53S AT K12 56107658 DIAGRAM WIRING KUBOTA GAS 2 DIESEL DIAGRAM ON PAGE 3 THROTTLE INPUT GRABLU K K GRABLU GRABLU CONTROL REMOVE JUMPER WHEN SEAT SWITCH 12V FOR HIGH ASSEMBLY T OPTION IS INSTALLED 1 23 5 D 53S CB5 BLK GRN A A BLK GRN 1 1 15 xi IGN RED BLK gt gt ORNIGRN 1 2 2 PINK PINK AKLA IGN SW INPUT GRN WHT 28 GRNWHT2 2 SWITCH IGN CIRCUIT BREAKER 10 AMP GRN RED C lt 4 C GRN RED 3 415 WHT GRN D lt D WHT GRN4 1 FACO 1 SENSOR GASOLINE PINK __B cB PURPLE ait EXCITE COOLANT TEMPERATURE rj d OUTPUT TAN PINK TO MAIN MACHINE CB4 CONTROLER 1 GRN BLU 1 42 VIO 1 2 BLK 4 h 3 VIO CIRCUIT BREAKER 20 AMP HOUR METER YEL BLK 1 P3 AND R3 ARE NOT USED L P MODEL SN d VIO O GRA BLK 1 2 ur SENDER FUEL GAUGE FUEL A LP12 i
78. DOOR L5 E amp GRANT 18 1 X101 VALVE 5 HOPPER UP DOWN Z gt 1 22 2 BERI TET X99 H CE PINK 16 2 1 22 2 RED GRA 18 i 86 85 1 1 VIO 18 12 1 2 1 2 T 1g VIO 185 CIR BKR 10 CIR BKR 20 AMP 1 BLU PINK 16 1 3 VALVE S3 SIDE BROOM ee RELAY NEUTRAL 16 1 5 X97 VALVE S2 MAIN BROOM K6 16 z 1 22 2 BRN BLK 18 2 X96 86 85 p i E 117 7169 2 GRN GRA 18 1 NOTE 18 20 15 USED WITH VIO 18 2 E z ENGINE SYSTEM re MISTING PUMP OPTION 30 202 K5 Mum MOTOR ASM WIPER lt 6 85 22618 0 INCLUDES 2 SPEED SWITCH Uu NOTE FOR DIESEL WIRE MENG PUMP ny lt 985 VALVE S4 DUST CONTROL AS SHOWN ON SHEET 2 i ag a X188 i X98 52 E5 z Zu _GRN YEL 16 4 92 58 ne GRNYEL 16 OPTIONAL ee gt CONNECTOR 1 2 5 2 E 2 RELAY SIGNAL LIGHTS 2 T OPTIONAL ORN 16 1 VALVE S1 HOPPER DOOR CLOSE OPEN s T mop RED 8 1 46 EE is L6 1 22 2 BLU WHT 18 1 i lt 9 R2 2 B __ 18 1 2o A gl B d 9 BLK 18 13 2 1 VALVE 56 HOPPER UP BYPASS eum BLK 18 18 B B A SERRE dae TL ali SP13 P LAMP TROUBLE BLK 1 1 1 22 2 BLU GRA 18 1 OPTIONAL DRIVE PEDAL SENSOR 5K OHM BLK 6 1 Sal ZOLL a cz 5 5 X82 CHASSIS GROUND 5 2 amp TaaA x LP6 1 1 VIO 18 11 4 1 BLK 6 1 oa a a a o oO
79. ED 16 1 X50 Hopper Interlock RED BLK 18 1 Me B 6186 xen ORN BLK 18 1 eo B BLK187 Three pin Connector Delphi 12162182 ID Name WireColor BRN WHT 18 1 reaa Sensor 5K Ohm ORN GRA 18 1 YEL GRA 18 1 Electrical System 64 Service Manual SW8000 Electrical System 65 Two pin Connectors Deutsch DT06 2S b Nme 1 VIO 18 4 X86 11 Hopper Door Close Open Valve 51 EN 2 BLU WHT 18 1 X96 L2 MainB Valve S2 1 18 7 Main Broom Valve ie GRN GRA 18 1 Service Manual SW8000 Electrical System 66 Troubleshooting Problem 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 Perform a load test on the battery and replace if necessary Note Refer to the individual machine system sections for electrical troubleshooting procedures Specifications Coil Operating Current 160 mA Coil Resistance 85 5 ohms SPDT Relay R1 R2 R3 R4 R5 and R6 Pull in Voltage 8 volts Release Voltage 1 0 to 5 0 volts Service Manual SW8000 Wiring Diagrams p n 56382530 Rev D Note Refer to the individual machine system sections for the system ladder diagrams an
80. EN 18 178392 6 CONN 171662 5 TERM 172888 2 SEAL BLACK 16 BLACK 16 BLACK 16 BLACK 12 BLACK 16 LABEL 5 02 HEATED 02 SENSOR POST CATALYST ALL GOLD BLACK LT GREEN 18 gt PED 12160825 CONN PED 12177150 TERM GOLD PED 12160826 LOCK 12089678 SEAL GROUND BMM BLACK 1 RING PINK 18 PURPLE 18 BLACK RED 16 a PINK YELLOW 16 OK BLUE 18 LT BLUE PINK 18 LI GREEN YELLOW 18 UNUSED PURPLE YELLOW 18 VSW CHARGE INDICATION FUEL PUMP FUEL PUMP AUX PWM 2 START COMMAND L AUX DIG 1 FUEL SELECT 5 DK BLUE ORANGE 18 BLACKZLT GREEN 18 LT GREEN RED 18 BLUE PINK 18 BLUE WHITE 18 LT GREEN BLACK 18 Pitt tte ty LT GREEN PURPLE 18 FPP1 SV RTN Sv EXT A B C D E F G H J K L M N P R S Sv EXT2 CONNECTOR 1 PED 15326863 CONN PED 12191819 TERM PED 12191153 SEAL PED 15305171 CAVITY PLUG E fimm VEHICLE INTERFACE CONNECTORS VIC 10 12 PINK DK GREEN 16 POWER RELAY 868 096 SEAL STARTER RELAY IGNITION 015200042 FUSE HOLDER 01520072 COVER 913 087 001 TERMINAL PINK DK GREEN 16 lo BLUE WHITE 18 NOT USED AUX PWMS RECIRC AUX PWMS TACH GROUND AUX PWM1 AUX ANA PU2 AUX ANA PU3 GOV SELECT 2 GOV SELECT 1 AUX 0162 AUX 0163 WHITE BROWN 16 BROWN WHITE 16 YELLOW DK BLUE 18
81. Hub The Rear Wheel Assembly and attached Cylinder Drive Wheel Hub fit onto the keyed tapered shaft on the Drive Motor A Slotted Nut and Cotter Pin hold the Drive Wheel Hub and attached Rear Wheel Assembly onto the Drive Motor shaft The Drive Motor is bolted to the Drive Yoke Weldment The Steering Cylinder extends and retracts to rotate the Drive Yoke Weldment and attached Drive Motor Drive Wheel Hub Rear Wheel Assembly about the Drive Yoke Pivot Pin to steer the machine Electrical Schematic and Circuit Description The only electrical component associated with the traction wheel system 1s the 5K Ohm Drive Pedal BRN WHT Sensor referred to as the Rotary 2 2 21 Sensor the Parts List 5K Machine 12 2 9RN GRA Wiper 2 Ohm Drive Pedal Sensor is a rotary Controller 39 3 YELIGRA Pot Low potentiometer that 1s coupled to the Lever Weldment Refer to the lower drawing on the preceding page The resistance through the 5K Ohm Drive Pedal Sensor varies according to the rotary position of the Lever Weldment Drive Pedal Sensor 5K Ohm The A2 Main Machine Controller senses the resistance through the 5K Ohm Drive Pedal Sensor This resistance must be within a preset deadband range that indicates that the piston pump is in the neutral position before the engine starter is allowed to operate This is a safety feature to ensure that the piston pump is in its neutral position when the engine
82. LK 18 9 She a d 3321 n VIO 16 2 BLK rope 18 21 GRA18 3 D 2 D GRA184 1 2 RED X MET YEL BLK 18310 1 x m cc T 6 85 VIO BRN 18 1 Ie OPTIONAL PUMP MISTING SP18 im T x oaoadoo 75 2 SWITCH LOW LP PRESSURE LP5 2 B co 1 67 X76 MY LAMP RIGHT REAR TAIL BRAKE vj gt Ar e Sa 2 1 252 o 87 WHT YEL 18 1 B dor OPTIONAL 5 2 0 BLK 18 23 lt 2501 dp CIR BKR 15 AMP 20 AMP BKR 70 AMP RELAY HORN aga 1 18 9 STARTER X211 VIO 16 3 um X128 X127 C VIO 187 GRN YEL 18 4 VIO 16 3 X BLK 18 22 SP5 GRA ORN 18 1 A HEAD LIGHT RIGHT VIO 16 3 oZ BLK161 _ 2l B VIO 18 8 E gt z BLK 18 37 B B SP11 pik 1812 501 A VIO 18 9 3 5 906 85 YEL WHT 18 1 x21 m x E 30 d YEL BLK 16 2 3 o 2 87 16 1 LP3 VIO 18 9 2 CBSO 6 cB GRA RED 14 1 VIO YEL 18 3 2 1BLK So WHT E VIO 18 10 RELAY LIGHTS x SP12 YD VIO 18 11 BKR oamp CIR BKR 10 BKR 20 Ka VIO 18 1 LAMP RIGHT FRONT SIGNAL C VIO 18 12 IGNITION ACCESSORY 204 SHAKER 326 85 YEL RED 18 1 OPTIONAL X169 X166 VIO 14 3 B VIO 18 13 MIO 18 20 VIO 18 15 30 87 BLU GRN 14 1 L7 E RELAY SHAKER VALVE S7 HOPPER
83. M Illuminates when the hopper mechanism 1 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 Lower Hopper Switch Q Lowers the hopper from the raised position after emptying the hopper Raise Hopper Switch R Raises the hopper for emptying Main Controller Fault Code Light S Flashes out the fault code for the controller Refer to Main Controller Error Codes described on page 36 for a listing of the specific error codes Service Manual SW8000 Control System 33 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 Most low and medium power outputs are controlled with power MOSFET transistors and very high power devices are controlled with external relays Another function of the Main Machine controller is to detect any system failures and flash out an error code with the faul
84. MP K7 WHT GRN BLK CBA COIL RELAY 87 RED 1 1 2 WHT VIO 87 US CIRCUIT BREAKER 20 A AGE DIESEL ONLY 69 Service Manual SW8000 Wiring Diagram Kubota Gasoline Engine p n 56107658 Rev A PINK DK GREEN 18 1 COIL CYL 1 YELLOW 18 is fl PURPLE WHITE 18 21 WHITE PURPLE 18 Im PURPLE ORANGE 18 2 GRAY BROWN 18 uL ll JUNCTION MUST BE MADE 3 6 FROM SENSOR CONNECTOR GASOLINE SENSOR INTERFACE PINK OK GREEN 18 1 COIL CYL 3 RENE X fl SWS _ 6195 0003 CONN SWS_ 8100 1429 TERM FIRING ORDER 1 3 4 2 SWS_ 7165 0118 SEAL OW BLACK 18 PINK DK GREEN 18 1 COIL CYL 4 INAL GOLD 1 SPK SPK COILIB PED 12160482 CONNECTOR PED 12048074 TERMINAL PED 12160480 LOCK PINK DK GREEN 18 1 COIL CYL 2 wn fl 13 WHITE LT GREEN 18 14 BLUE PINK 18 WIR 10 TURN 200 DEG QOT FULL LENGTH 15 BLUE WHITE 18 16 20 BLACK LT GREEN 18 1 DK GREEN ORANGE 18 DK GREEN WHITE 18 fe 23 LTGREEN 16 4 AUX ANA PUD3 28 PURPLE ORANGE 18 29 _RED WHITE 18 WIRES TURNST3E SPEED 30 RED BLACK 18 O 262 49 CX SV EXT 2 31 LT GREEN PURPLE 18 SV RTN 2 32 LT GREEN BLACK 18 PULSE IN 35 GOV 1 34 GRAY DK BLUE 18 35 LT BLUE 18 35 LTBLUE 1B SPESE 36_YELLOW GRAY 18 ECT 38 1T GREEN WHITE 18 39 YELLOW DK BLUE 18 40 DK BLUE YELL
85. NE BLK VIO 1 2 BLUGRA 4 d SWITCH HOPPER INTERLOCK VALVE S6 HOPPER UP BYPASS CHECK ENGINE OUTPUT L7 MIL INPUT J2 5 GRN YEL vis BLKWHT qz FROM ENGINE SYSTEM VALVE S7 HOPPER OPEN CLOSES WHENFILTERIS 55 18 PLUGGED BBN T Jog WHT GRA 1 2 BLK VALVE S8 DUST CONTROL BYPASS SWITCH DUST CONTROL FILTER YEUGRN J19 MAIN MACHINE H2 VALVE 59 HOPPER LOWER CONTROLLER CLOSES WHEN TANK GRA YEL IS EMPTY 1 5 2 BLK VIO 1 2 GRN BRN 445 J2 4 4 SWITCH LOW LP PRESSURE BACK UP ALARM OPTIONAL K1 OPEN WHEN VIO 212 ORNIBLK BROOM 8 BLK RELAY HORN 2 SWITCH MAIN BROOM K2 BLK VIO YELWHT 44g 10 RELAY LIGHTS J1 20 BLK K3 J2 14 BLK VIO YEURED 444 RELAY SHAKER 51 1 4 2 13 4 ENGINE SPEED PS2 f 12 43 2 44 8 COMMON ANODE HORN TPS3 DI 1 2 T J4 10 lt i LIGHTS LED SERVICE INDICATOR TPS4 4 E 1_ 2 43 11 LED DUST CONTROL FILTER SHAKER ves p3 55 LED GLOW PLUG me J3 10 ne 9 TOUCH PAD DISPLAY TOUCH PAD DUST CONTROL LED SERVICE ENG MIL SWITCHES TER DE 1 2 J3 9 J4 2 S SIDE BROOMS LED LOW FUEL TPS7 D 12 dE J4 9 S HOBBERBOOHDBEN LED HOPPER TEMP TPS8 07 44 4 lt t J3 6 LED DUST CONTROL HOPPER UP BE TPS9 47 LED HOPPER NOT DOWN 2 J3 8 HOPPER DOWN TPS10 1 12 J3 7 HOPPER DOOR CLOSE COMMON GROUND T Service Manual
86. OW 18 IVS AUX ANA 41 TAN DK GREEN 18 BRAKE AUX DIG 3 GOV2 AUX DIG 4 42 GRAY RED 18 43 GRAY 18 TACH 44 18 VSW 45 AUX ANA PUD2 AR MEE 47 PURPLE LT BLUE 18 48 LT BLUE DK BLUE 18 49 FUELSELECT AUX DIG 1 BLACK YELLOW 18 WIR TURN 60 D 90 Knock BLACK 3H 0 0 O OSO 5 5922 a n 53 BLUE ORANGE 18 54 PURPLE YELLOW 18 FPP2 2 1 5 61 BLACK YELLOW 18 62 BLACK WHITE 18 3 66 BROWN YELLOW 18 67 BROWN WHITE 18 68 69 BLACK 16 RED TAN 16 a 72 PINK BLACK 18 74 GREEN YELLOW 18 7 LI L 75 76 77 78 TAN BLACK 18 e 79 16 a 2 H IL 79 RED TAN 16 87 DK BLUE 18 88 89 PINK YELLOW 16 AUX PWM4 REC FP REC AUX REC 90 BLACK RED 16 FUEL PUMP AUX PWM3 SUMITOMO 6195 0043 CONN SUMITOMO 8100 1429 TERMINAL SUMITOMO 7165 0118 SEAL INJ CYL 1 BLACK YELLOW 18 BLACK 18 Jis KNOCK SENSOR BOSCH_ 1 928 403 126 CONN gt BROWN LT BLUE 18 1 PINK DK GREEN 18 SUMITOMO 6195 0043 CONN SUMITOMO 8100 1429 TERMINAL SUMITOMO 7165 0118 SEAL BROWN LT GREEN 18 PINK DK GREEN 18 SUMITOMO 6195 0043 CONN SUMITOMO 8100 1429 TERMINAL SUMITOMO 7165 0118 SEAL
87. PPS TZ tL Control 15 GPM Oil Cooler PSI Up Down System 037 UTI 3 YI Mn eo 2 n MNT EN Hydraulic Manifold Assembly Hopper Lift Cyl 2 5 x 15 125 x 1 25 AC Hydraulic Compressor Motor a pF eg EIE 2400 MA UG _ AC Option Drive Wheel System Reservoir Service Manual SW8000 Options and Accessories Description Left Hand Side Broom Rear Bumper Kit For Non Cab models Tilt Steering Kit Illustration 141 Service Manual SW8000 Options and Accessories 142 Description Illustration Raised Air Intake Kit for use with Overhead Guard Hopper Temperature Sensor Kit Fire Extinguisher Kit For Non Cab models Service Manual SW8000 Options and Accessories 143 Description Illustration Hopper Bottom Plate Kit Suspension Seat Kit Service Manual SW8000 Options and Accessories 144 Description Illustration DustGuard Premist Kit Seat Belt Kit Service Manual SW8000 Options and Accessories 145 Description Illustration Right and Left Side Broom Guard Kits Plugged Filter Switch Kit WM Service Manual SW8000 Options and Accessories 146 Description Illustration Litter Vac Kit Raised Air Intake Kit with
88. 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 Nilfisk Advance Service Manual SW8000 198 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 The piston pump and drive motor hydraulic system 1s a closed system but allows for oil leakage through the drive pump for lubrication and cooling purposes This leaked oil returns to the reservoir through the case drain and requires make up oil that 1s supplied to the drive pump through the charge circuit from the oil cooler and filter Piston drive Pump and Drive Motor The Piston Pump is
89. TE il Fi i i Oil Filter 3 2 Spin the Oil Filter Cartridge off of the Oil Head Filter Head 3 Install the new Oil Filter Cartridge onto the Oil Filter Head Oil Filter gt Cartridge m a To Clean the Hydraulic Oil Cooler Clean the engine radiator and hydraulic oil cooler every 30 hours of operation as follows Caution Wear Safety glasses when cleaning the engine radiator and hydraulic oil cooler 1 Tip the Engine Cover back then disconnect the cable latch on the left side of Engine Cover to allow the Cover to tip all the way back and out of the way 2 Turn the locking mechanism at the top of the Hydraulic Oil Cooler to allow the Cooler to tip back away from the Radiator for easy access 3 Blow out the Radiator and Hydraulic Oil Cooler with compressed air or clean using low pressure water to rinse any debris from the fins Service Manual SW8000 Hydraulic System 134 Caution Do not use pressure washer 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 Hydraulic Oil Cooler to its upright position and latch it into place 5 Lift the Engine Cover up and reconnect the cable latch Troubleshooting General Troubleshooting Problem Correction General poor Low oil hydraulic level Check the oil level in the reservoir and hydraulic add oil as necessary perform
90. UGE COMBINATION SENDER OIL PRESSURE TAN 67 Service Manual SW8000 Electrical System 68 Wiring Diagrams p n 56382530 Rev D sheet 2 of 3 VIO BLK VIO GRN RED GLOW PLUG SIGNAL 1 11 ACC INPUT J2 6 lt GRN RED DIESEL ENGINE ONLY L1 VIO 1 2 BLUMHT 44 IGN INPUT 12 11 PINK ene VALVE 1 HOPPER CLOSE OPEN K4 L2 J1 18 GRAWHT VIO 1 2 GRN GRA 44 5 RELAY NEUTRAL TROTTLE OUTPUT TO ENGINE SYSTEM GRA BLU L3 ic GRA BLU 12 V FOR HIGH SPEED VIO 1 2 BRN BLK J1 3 VALVE 3 SIDE BROOM J2 1 BRN WHT 26 K 2 2 OBNIGRA vio 2 1 3 BLK ORN BLU ORN BRN BLK R2 SWITCH MISTING PUMP gt did eee HAE DRIVE PEDAL SENSOR 5K OHM L4 CLOSES WITH MO 1 2 BRN YEL 44 HIGH HOPPER VALVE 54 DUST CONTROL TEMPERATURE 5 aa 2 t 3 BLK VIO RED GRA RELAY COMPRESSOR SWITCH HOPPER TEMP L5 OPTIONAL J1 5 OPTIONAL VIO 1 2 RED GRA CLOSED WHEN VALVE S5 HOPPER UP DOWN DOWN S Ba L6 RED BLK
91. achine to be steered manually with the engine off Rotary 4c Valve Check Valve Rotary Meter A T To Oil Cooler and Filter i 2 0 A GPM 4 B Hydraulic Manifold Pump Assembly 2400 RPM Reservoir Service Manual SW8000 Steering System 180 Component Locations The following components are included in this section Steering Wheel and Steering Control Unit Steering Cylinder Steering Wheel and Steering Control Unit The Steering Wheel rotates the splined 7 shaft on the Steering Control Unit which Steering controls the hydraulic oil flow to the Ip Y steering cylinder The Steering Control Unit is mounted to the frame and is located underneath the Steering Plate Steering Control Unit mounted underneath Steering Plate Steering Cylinder The Steering Cylinder is located at the bottom rear of the machine and is Drive Yoke connected to the machine frame and the Drive Yoke Weldment P Steering P f Cylinder a Drive Yoke Weldment and Steering Cylinder as viewed from underneath the machine Service Manual SW8000 Steering System 181 Maintenance Ay 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 Lubricate the steering Bearing Con
92. alve S7 then to the retract lower port B on the Hopper Dump Cylinder to open the hopper door The oil from the extend upper port C on the Hopper Dump Cylinder goes through the energized Hopper Close Open solenoid valve S1 through the de energized Hopper Open solenoid valve S7 then returns to the Reservoir Service Manual SW8000 Hopper System 120 Close Hopper Door Hopper Dump Cylinder Closes Hopper Door E B To From Steering Steering Hopper 4 2 Close Open VI 1 Hopper t Oil Cooler and Filter T 1 Gear Pump i 2400 RPM Ao CIR __ 224 eee Reservoir 2 Note The hopper door only be opened and closed manually when the hopper is not down DIR The hopper door closes automatically when the broom is off or the hopper is raised When the Close Dump Door Switch on the control panel 1s pressed the A2 Main Machine Controller energizes the Hopper Open solenoid valve S7 The hydraulic oil is directed through the energized Hopper Open solenoid valve S7 through the check valve in the de energized Hopper Close Open solenoid valve S1 then to the extend upper port C on the Hopper Dump Cylinder to close the hopper door The oil from the retract lower port B on the Hopper Dump Cylinder goes through the energized Hopper Open solenoid valve S7 then returns to the Reservoir Service Manual
93. ance Hydraulic oil temperature too high Check for any restrictions to or from the oil cooler and correct as necessary Clean the cooling fins on the oil cooler to ensure adequate airflow through the cooler Hydraulic oil filter plugged Replace the oil filter cartridge Gear pump failing Check the output pressure from the gear pump If below specs repair or replace the pump Contamination in the hydraulic system Drain flush and refill the system General Information Regarding Checking Hydraulic Pressures Accurate measurements are the key to troubleshooting a hydraulic system Once you obtain accurate measurements you can compare them to the specifications to analyze a problem You can use digital tachometers flow gauges meters or pressure gauges to troubleshoot the hydraulic system The pressure gauge should have a range of 0 to 3000 psi see the Special Tools section The flow meter must be rated to 3000 psi and 10 gal min The most convenient way to check for oil flow 1s to check the RPM of the motor that 1s performing poorly Refer to the following tables to determine the motor RPM If the motor speed 1s correct the pump 1s producing the correct amount of oil flow However this does not mean that 1f a motor 1s running too slow the problem is in the pump The following information should be used to check for correct system pressure The readings are nominal measured figures and there will be variations due to manufact
94. ated to the dust control system Dust Filter Vacuum Motor DustGuard Nozzles Plugged Filter Switch Shaker Motor Dust Hopper Hopper Temp Switch Misting Pump c EE tg he Ci er eI Hopper Temp amp Plugged Filer Switches LA Shaker Motor Relays Dust Filter Misting Pump Hydraulic Valves Dust Hopper and Blower Inlet Vacuum Motor eee DustGuard Spray Nozzles 43 Service Manual SW8000 Dust Control System 44 Maintenance and Adjustment Dustguard Spray Nozzle Cleaning 1 Dust Control Filter Cleaning For easier access to the nozzles raise the hopper shghtly Place a container underneath the nozzles to catch any water that may leak from the hoses 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 Rinse the nozzle cap spray nozzle and check valve strainer in clean water to remove any accumulated dirt or sediment If necessary rinse or soak the components in vinegar or other commercial cleaner to remove any mineral deposits Reassemble the nozzles by following the above steps 1n reverse order protection when cleaning the filter Clean the filter in a well ventilated area Caution Avoid breathing dust or getting debris your eyes Wear safety glasses and respiratory Lift the hopp
95. ation flap Orientate flap down when reinstalling Engine Maintenance 150 Hours At 150 hour intervals it is recommended that the following service be performed Change oil and filter clean and inspect spark plugs check all engine belts condition and adjustment check battery charge and level check cooling system hoses and clamps and check general condition and performance of engine AN Note See the Other Manuals Available section for a complete list of the engine manuals that c are available Hydraulic Oil Caution To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic system Check the Hydraulic Oil Level Unlatch and swing open the Oil Reservoir Fuel tank Cover Remove the reservoir cap to check the oil level The hydraulic oil level should be just above the bottom of the screen filter inside the filler neck of the reservoir Add SAE 10W30 motor oil if it is below this level Change the oil if major contamination from a mechanical failure occurs Change the Hydraulic Charge Oil Filter once a year or every 1000 hours Service Manual SW8000 General Information 23 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 Wear safety glasses when cleaning
96. ator Cab Filter Cover Heater Hoses Heater Control Assembly HVAC Relay Figure 3 Heating System Components Options and Accessories 153 Service Manual SW8000 Options and Accessories 154 Air Conditioning System Components Refer to Figure 4 17 19 21 28 25 21 29 ol Evaporator Heater Unit 18 Binary Pressure Switch 20 A C Compressor 22 Air Filter 24 Coolant Tube From Engine Radiator 26 Heater Control Assembly 28 Compressor Motor Hydraulic Valve 30 HVAC Relay Figure 4 Air Conditioning System Components A C Condenser A C Receiver Dryer Hydraulic Compressor Motor Cab Filter Cover Heater Hoses Accessory Gear Hydraulic Pump Compressor Relay _ pL d T4 gt L N 9 A Included with 27 Service Manual SW8000 Options and Accessories 155 Maintenance machine maintenance Warning Turn the key switch and remove the key from the ignition switch before performing any Maintenance Schedule Maintenance intervals given are for average operating conditions Machines used in severe operational environments may require service more often Maintenance Item Daily Weekly Monthly Hours Check for any coolant hydraulic or refrigerant leaks Note Refrigerant leaks can appear as dirty oily areas around A C components and fittings Check the cab filter and clean or replace as necessary Note The cab
97. blem there may be the APECS 3000 Controller a problem with the A2 Main Machine Controller or APECS 3000 Controller Service Manual SW8000 Engine System Diesel 89 Engine Overheating Problems When the Coolant Temperature Switch 98 senses that the coolant temperature 1s too high 1t 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 nspect and clean the radiator and hydraulic oil cooler Check for correct operation of the belt driven engine cooling fan slippage e Check to see that the engine thermostat opens Check for correct water pump operation Check the engine crankcase oil level Check for air trapped in the cooling system Refer to the Engine Coolant Replacing Engine Coolant section Check the coolant temperature switch for correct function as replace 1f necessary Loss of Oil Pressure Check for possible causes for low oil pressure such as Engine crankcase level is low ncorrect oil viscosity Fault in the oil pressure switch 528 Excessive engine wear or defective internal oil pump relief valve APECS 3000 Controller Fault Codes The Woodward APECS 3000 Controller is capable of identifying some fault conditions
98. bricating Oil Note Refer to the Kubota Diesel Engine 05 Series Work Shop Manual for the suitable American Petroleum Institute API classification of engine oil according to the engine type with internal EGR external EGR or non EGR and the Fuel Type Used Service Manual SW8000 General Information 22 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 1s 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 1nner 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 1s replaced Never attempt to clean the Inner Safety Element To clean the Primary Filter Element unsnap the 2 clips at the end of the air filter housing and remove the end housing Pull the primary element out Clean the element with compressed air maximum pressure 100 psi or wash it with water maximum pressure 40 psi DO NOT put the element back into the canister until it is completely dry Air Mechanical Vacuum Filter Service Empty dust from the outer plastic housing by squeezing the rubber Indicator Loc
99. ce Schedule Item Service Interval Every Every Every Every Every Every Every Every Every Every Every 100 150 200 400 500 800 1500 E 9 Y Two 50 hrs 75 hrs Year hrs hrs hrs hrs hrs hrs hrs hrs Years Check fuel pipes and X clamps Change engine oil Change oil filter cartridge Clean air filter element Clean fuel filter element Check fan belt tension and for Check water pipes and Change fuel X filter cartridge wes LLL uus X Interior Change X radiator coolant manne Lo oL x nuls X injection nozzle Change air filter X element Check valve X clearance Change water pipes and X clamps Change fuel pipes and X clamps Change the engine oil and filter cartridge after the first 50 hours of operation Maintenance intervals per EPA instructions 81 Service Manual SW8000 Engine System Diesel 82 Engine Oil Check the engine oil level when the machine 1s parked on a level surface and the engine 1s 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 wi
100. d circuit descriptions Notes 1 Reference 56382531 Wiring Harness Diagram RED al BLK a ae RONDA BAITERY 5 a eralda eea a ela oe MERE CB9 E1 K8 87a HEATER TEMP i RED 1 2 RED VIO 30 87 VIO GRA CONTROL S BLK CIRCUIT BREAKER 20 A M6 M9 RELAY 530 1 YEL a RED RED BLK VIO GRA B ORN M T EIE 35 MOTOR BLOWER MOTOR PRESSURIZED AND HEATED CAB SWITCH FAN M10 2 2 1 WHT A 2 BLOWER MOTORS FOR A C RED BLK SW SPST M HVAC OPTION mes K9 RELAY CONDENSOR FAN wur MOTOR BLOWER MOTOR Bk S33 534 K10 87a L10 BLK WHT i L 2 GRN 1 2 GRNWHT30 87 BLUBRN 1 2 BLK K3 87a Mg THERMOSTAT RELAY COMPRESSOR VALVE COMPRESSOR RED 30 87 BLU mitos BLK SWITCH PRESSURE i RELAY
101. der operator s seat and pump a small amount of grease into bearing assembly Also every 150 hours apply light machine oil to maintain free movement of all general pivot points Example the seat adjustment track and broom door hinges etc Broom and hopper pivots use composite bearings lubrication 1 not required Caution For the protection of the environment when servicing any of the machine s lubrication fluids they must be disposed of safely in accordance with your local environmental regulations recycling Examples of machine lubrication products Engine crankcase oil Engine crankcase oil filter Hydraulic system oil Hydraulic system oil filters Engine Coolant Caution Do not remove the radiator cap when the engine is hot To check the engine coolant level first unlatch and open the Oil Reservoir Fuel Tank Cover then tilt the Engine Compartment Cover and observe the coolant level on the Coolant Recovery Tank For Cab equipped models the cab panels and left side window must be opened in order to tilt the Engine Compartment Cover If the level 1 low add a mixture of half water and automotive type anti freeze Clean the radiator and oil cooler exteriors by washing with LOW RESSURE water every 30 hours Service Manual SW8000 General Information 21 Caution Do not use a pressure washer on the raditor or hydraulic oil cooler Doing so may bend the Ay cooling fins reducing cooling capability 2 Service Note The o
102. described below a Liberator Mode Automatic operation with manual operation by pressing the shaker switch When active the shaker will be on for second and off for gt 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 4 Press the Shaker switch to toggle through the setting Liberator Mode Both Shaker and Fan lights on Continuous Mode Shaker light on Manual Mode Neither light on 5 To exit turn the keyswitch off Troubleshooting Main Controller Error Codes The following table lists the main controller error codes When an error code is present the Error Code lamp S will flash out the specific 2 digit code s Count the flashes for each digit There will be a short pause between digits and a long pause between error codes or before repeati
103. ds its hydraulic oil flow to the tank when S6 is de energized 0 volts Service Manual SW8000 Hydraulic System 137 Specifications General Specifications 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 Piston Pump Continuous pressure 3000 psi 206 8 bar Maximum pressure 5000 psi 344 7 bar Main Loop Relief Valve Set Point 3000 psi 206 8 bar Type external spur gear positive displacement Gear Pump Displacement 1 02 CIR Solenoid Valves 51 52 53 54 Nominal Coil Resistance 9 ohms Hydraulic Manifold 55 S6 57 and measured on one machine Assembly 59 Solenoid Valve Nominal Coil Resistance 6 5 ohms 58 measured on one machine Service Manual SW8000 Hydraulic System 138 Hydraulic Manifold Assembly 54 Only Installed on Models with Litter Vac Kit Hydraulic Manifold Assembly ES a Hydraulic Circuit Function Component Description Hopper Close Open Solenoid actuated 2 2 directional poppet pilot 51 82 Main Broom joperatedcart dge valve oolenoid actuated 4 2 directional spool direct acting 57 cartridge valve Hopper Up Down Solenoid actuated 2 2 directional poppet direct acting Lower Hopper cartridge valve Solenoid actuated 2 2 directional poppet pilot
104. duced when the hopper 1 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 Rotate or Replace the Main Broom Because the Main Broom Motor always turns the same direction the bristles on the broom will eventually become curved opposite of that rotation Sweeping performance can be improved by removing the broom and turning it around end for end This procedure known as rotating the main broom and should be performed every 15 hours of operation BA Note This procedure does not apply to the optional chevron broom because that broom has et directional bristles Caution Broom bristles be sharp Wear gloves protect your hands when handling the broom 1 Turn the Ignition Switch to Off 2 Put the Main Broom Lever in the Up position 3 Open the broom access panel 2 4 Pivot the idler arm 3 away from the main broom core 5 Pull the Main Broom 1 off the motor shaft and out of the machine 6 Remove any string or wire wrapped around the broom Also inspect the skirts at the front back and sides of the broom housing The skirts should be replaced or adjusted if they are torn or worn to a height of more than 1 4 inch 6 35 mm off the ground 7 Turn the broom around end for end and slide it back into the broom housing Make sure that the lugs on the broom core enga
105. e If your machine is equipped with DustGuard system you ll need to disconnect the hose coupling the DustGuard tank before you remove the DustGuard tank from the machine 4 Start the engine and observe the wheel rotation with the engine idling If the wheel 1s rotating either forward or reverse with the foot pedal 1n the neutral position adjust the position of the Lever Weldment as follows 5 Loosen the two 1 4 20 x 62 Screws holding the Lever to the Lever Weldment 6 Rotate the Lever Weldment as necessary until the wheel stops turning 7 Tighten the two 1 4 20 x 62 Screws 8 Shutthe engine off 9 Reset the foot pedal deadband setting Refer to the Control 1 5 A System Main Machine Controller oe Programming Hydrostatic Neutral Position and Dead band section 10 Reinstall the center cover assembly DustGuard tank Lever Weldment EN 11 Reconnect the DustGuard tank hose coupling if applicable Service Manual SW8000 Wheel System Traction 207 Troubleshooting 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 the machine is stationary when the foot pedal is in the when the foot pedal is neutral position in the neutral position
106. e Injector Pump fuel line 8 When no more bubbles can be seen at the Bleed Screw and the fuel is running clear tighten the Bleed Screw Service Manual SW8000 Engine System Diesel 87 do need to perform these steps to bleed the fuel system at the injector pump fittings e Service Note Normally steps 9 through 17 below are not required to bleed the fuel system If you M and injector fittings make sure to follow the safety warning information below outlined in steps 9 through 17 below make sure to wear protective gloves to protect Warning If you need to bleed the fuel system at the injector pump fittings or injector fittings as your hands from the high pressure diesel fuel present at these fittings This high pressure fuel is capable of piercing the skin and injecting diesel fuel into the skin which can result in severe personal injury 9 If necessary slightly loosen one of the four Injector Pump Fittings on the top of the injector pump 10 Crank the engine to bleed any air from the Injector Pump Fitting 11 When no more bubbles can be seen at the Injector Pump Fitting and the fuel is running clear tighten the Injector Pump Fitting 12 Repeat steps 9 through 11 above for the other three Injector Pump Fittings Injector Pump Fitting 4 recommended that you start with the fitting on the shortest line and finish with the 2 Service Note If you need to bleed the fuel system at the injector
107. e engine cooling system Check the coolant level in the overflow tank and radiator nspect and clean the radiator and hydraulic oil cooler e 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 Check the engine crankcase oil level Check for air trapped in the cooling system Refer to the Engine Coolant Replacing Engine Coolant section Check the engine coolant sensor for correct function as replace 1f necessary e Check for combustion gasses in the coolaning system Service Manual SW8000 Engine System Gasoline LPG 108 Specifications WG1605 G E3 WG1605 L E3 Gasoline fuel LPG fuel Number of Cylinders Four Gasoline engine LPG engine 0 45 rad 26 before T D C 0 35 rad 20 before T D C 3000 min 1 rpm 3600 min 1 rpm 0 17 rad 10 before T D C 750 min 1 rpm 800 min 1 rpm 750 min 1 rpm 800 min 1 rpm 1 3 4 2 Engine Oil Pressure Hot Factory Specification Allowable Limit E S UnadedAutmobleGasoine Commercial LPG 120 kg 265 bs Kubota Recommended LPG Fuel Commercial Propane gas only Specifications Equivalent to Propanes H D 5 of GPA standards Service Manual SW8000 Engine System Gasoline LPG 109 Shop Measurements The following information was gathered by measuring one machine While the values recorded cannot serve as true specifica
108. e function to normally be active Dust control vacuum motor will not stop Check the voltage at Misa EE iis No Coil failure Replace the the S8 solenoid valve i coil or the whole solenoid connector for 12 volts close to 6 5 ohms Valve failure Replace the valve or the whole solenoid Check for 12 volts between ves the J1 11 and J1 8 pins at the main control board Repair replace the wiring Replace the main control board Done 46 Service Manual SW8000 Dust Control System 47 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 VA Note In the decision tree below all function prerequisites are assumed to be true for the function OTA to normally be active Shaker motor will not run when switch is pressed Verify that the CB6 circuit breaker is not tripped Does the shaker LED illuminate when the shaker First verify that the LED is functional by observing it during machine initialization Yes Replace the main Then turn the machine off Press and control board switch is pressed hold the shaker switch and check for continuity between the J3 1 and J3 11 Yes pins on the ribbon cable connector Done No Replace the Check for 12 volts at the Yes Replace the shaker motor connector shaker motor Done Swap the shaker relay for an adjacent relay such as th
109. e horn or lights and check the shaker function Replace the shaker relay Check for 12 volts between ves Check the wiring for the J1 11 and J1 14 pins at loose connections the main control board or broken wires Replace the main control board Done Service Manual SW8000 Dust Control System 48 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 when the switch is on The misting pump will not Verify that the side broom s operate if the side broom s are enabled and turning are not running Troubleshoot the side brooms first If the side brooms are working then the control board is known to be working Verify that the CB8 circuit breaker is not tripped Check for 12 volts at the Yes misting pump connector Replace the misting pump Swap the misting pump relay Y for an adjacent relay such as E gt Replace the the horn or lights and check the misting pump function Done Unplug the relay Repair
110. e the air from the radiator as it fills the radiator with coolant Purge the Heater Circuit Another method 1 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 functions for reference Warning Before attempting to remove the heater hoses make sure The engine is switched off he machine coolant has cooled to a low enough temperature so as not to cause burns or injury to persons contacting the hoses or coolant cooling system temperature and pressure have decreased enough to allow you to remove the radiator cap to relieve the system pressure before removing the hoses TE EENAA E 72 27 3 pnm Coolant Supply from Engine Coolant Return to Engine S Coolant Return g trom Heater Core Figure 7 Valve Assembly Hose Functions Service Manual SW8000 Options and Accessories 161 Air Conditioning System M Note Refer to the schematics at the end of this chapter gt 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 trans
111. eck operation ofthe safety hopper suppor a e 18 Hener Dump Door ome 15 Headlights Gauges and Optional Accessories example rotating beacon backup alarm Dust Control Filter Shaker amp Vacuum Impeller 17 Tilt Steering Mechanism and Seat Adjustment lever 18 DustGuard OPT Water Pump Operation On Off Defect Codes Does Not Ref VISUAL INSPECTION ITEMS Comments circle Work 19 Side Broom Pattern amp Height Adj min bristle length 3 3 O clock to 11 inches Ss EM m Hopper Cover Gasket 22 Ww 23 Dust Control Vacuum impellerMotor S f t 25 Hopper Skiing amp Seals raise hoppertoinspe 212 28 Hope Dump Dow amp Sea tase A 27 Hope i ner s Hopper eck Swien Main Broom Pattern Adjustment min bristle wear 2 1 2 6 4cm length Sheet 1 of 2 Service Manual SW8000 General Information Main Broom Motor open left side access door to B L inspect A x 3 El com se Ene Ar Caner Benem Circuit Breaker Relay panel nF 35 Hydrostatic Dump Valve Dump Valve Hopper Up Transport Speed control Cam Cable Linkage Propulsion drive amp Accessory Pumps Hydraulic Reservoir System Hoses amp fittings Propulsion Pump Hydro Back Cable amp Clevis Connections C 42 Radiator amp Cooler Gore
112. een ee cEHEO ox Xv FOE PE ue wo 89 TESI eae 4 53993 495 9 94 25 x5 25 310 90 SDCCINGAUCNS 224044545 eR bee S RUE E S ROSSI ERAN URS SR EJ 92 Special Tools oaoa 93 Engine System 0 95 Functional Description 95 we eee hed nr dome SURE UAM x m RU S eR 95 Engine DESID ON ee ee ESOS Hee eee eee es 95 Kubota 1 6L Gasoline Fuel System lt 95 Kubota 1 6L LPG Fuel System lt 95 Engine Starter Circuit Description 96 Engine Protection Low Oil Pressure Shutdown 97 Engine Protection High Temperature 97 Engine Speed 97 Component Locations 4 26 ahd oon eee ERO DREW ERO HES o 98 LPG And Gasoline Engine Common Electrical lt 98 LPG ONLY Engine Electrical ana 101 Gasoline Petrol ONLY Engine Electrical and Fuel 102 Maintenance and 103 Maintenance Schedule
113. en 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 The illustration below shows the location Turn the valve 90 degrees this disengages the hydrostatic lock between the motor and pump The hydraulic propelling pump can be damaged if the machine is towed with the valve in the normal working position Reference the illustration below for the normal working setting vertical and the free wheeling towing setting horizontal Note If the tow valve is left in free wheeling horizontal position the propelling pump can t drive the machine FWD or REV No damage will result just re set valve to the normal working setting vertical NOTE Tow or push machine no faster than a normal walking pace 2 3 miles per hour and for short distances only If the machine is to be moved long distances the drive wheel needs to be raised off the floor and placed on a suitable transport dolly A i 4 a Free Wheeling 2 Towing Setting id nd Hydraulic Propelling Pump Tow Valve Service Manual SW8000 Technical Specifications General Specifications common to All Models Dimensions Side View Length Side View Length Width minimum Height Height w overhead guard Height w cab Ground clea
114. epeat for the other cylinders 13 Reassemble in reverse order Service Manual SW8000 Engine System Diesel Specifications Kubota V 1505 E3B Diesel Engine Type Water cooled four cylinder four stroke diesel engine 91 41 cubic inches 1 498 L 3 07 x 3 09 78 mm x 78 4 mm Counterclockwise as viewed from the flywheel end 3 14 to 3 53 MPa 32 0 to 36 0 kgf cm2 456 to 512 psi 2 26 MPa 23 0 kgf cm2 327 psi Fuel Injector Pump Bosch MD Type Mini Pump Fuel Filter Cartridge Type Fuel Pump Pressure 3 5 psi Fuel Pump Volume Capacity 30 GPM 113 6 LPM Fuel Injection Nozzle Mini Nozzle DNOPD Factory Specification Cranking Compression Allowable Limit Fuel System 140 kgf cm Injection Pressure Engine Oil API Service Class CF Recommended Lubrication System Engine Oil Capacity 6 34 US ats 6 L Oil Filter Full Flow Paper Filter cartridge type Cooling System Type Pressurized Radiator Forced Circulation with Water Pump 1 991 psi 13 73 MPa Forced Lubrication by Pump 92 Service Manual SW8000 Engine System Diesel 93 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 Actuator Voltage supply from APECS controller when cranking approximately 8 0 VDC S
115. er 1 31 neutral 1 214 full rev Low voltage reference output of potentiometer Not empty Engine running but no check engine signal Not available Not available 8 Z 42 3 42 4 Pedal low LP low switch Check eng input Glow plug input NC Dust filter switch Hopper interlock 4 81 C EL m o 2 down Not available On raised 9 02 5 02 temperature Ignition input 13 89 Main broom down NC Bat C N A Co e XO 2 i Nilfisk Advance 40 Service Manual SW8000 41 Dust Control System Functional Description The purpose of the dust control system 1s 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 created by the side brooms The vacuum based dust control system reduces airborne dust inside the hopper by pulling air through the hopper and through a filter to trap the dust inside the hopper DustGuard Spray System optional The misting pump pumps water from a separate reservoir to nozzles on the front of the machine The nozzles direct a fine stream of water onto the floor 1n front of the side brooms to help reduce the dust generated by t
116. er cover and prop it open with the cover prop rod Disconnect the Shaker Motor Electrical Connector Remove the 4 thumbnuts 5 that secure the shaker frame 6 and lift the shaker frame off the filter 7 Lift the filter out of the machine Inspect the top of the dust control filter for damage A large amount of dust on top of the filter is usually caused by a hole in the filter or a damaged filter gasket Vacuum the underside dirty side of the filter to remove loose debris Loosen additional stuck debris by gently tapping the filter against a flat surface such as a workbench or floor If additional cleaning is necessary you may use compressed air less than 100 psi but do so with caution Direct the air through the filter from the clean side to the dirty side When replacing the filter make sure the flow direction arrow is pointing up Service Manual SW8000 Dust Control System 45 Troubleshooting Dust Control Vacuum Motor will not Run The dust control hydraulic solenoid valve 1 normally active on when no power 1 present So the most likely cause 1s 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 For example the engine is assumed to be at run speed and the main broom is active Dust control vacuum motor will not run Verify tha
117. er solenoid valves S1 S5 S6 S7 and S9 when the Ignition Switch is on The A2 Main Machine Controller will ground and energize the solenoid valve corresponding to the function selected by the Operator via the Touch Pad Switches The Hopper Interlock Switch S4 must be closed hopper down before the sweeping functions can be enabled The Hopper Interlock Switch S4 must be open hopper up before the hopper door can be opened or closed manually Note The A2 Machine Controller programming logic for the hopper functions works as follows The engine needs to be at the high speed setting in order to raise or lower the hopper The A2 Main Machine Controller will automatically open the hopper door when the main broom is on lowered The A2 Main Machine Controller will automatically close the hopper door when the main broom is off raised or when the hopper is not down The hopper door cannot be closed manually when the main broom is on and the hopper is down The hopper must not be down and the main broom must be off in order for the hopper door to be opened or closed manually The main broom is turned off automatically and the hopper door is closed automatically when the hopper is raised not down Service Manual SW8000 Hopper System 116 Hopper System Hydraulic Diagrams Hopper Down Hopper Door Closed Hopper Dump Cylinder O Ej B To From Steering Steering S7 U AEZ H
118. es and Bearing Cups on the Drive Yoke Weldment Steering Lubricate the Pivot Point where the Cylinder Steering Cylinder is attached to the Drive Yoke Weldment Yoke Weldment gt Bearing Drive Yoke Pivot Pin Service Manual SW8000 Steering System 182 Troubleshooting Problem Correction The steering is hard or Not enough oil to the steering Check the pump output and correct as necessary jerky system Check the priority flow divider and correct replace as necessary There is binding at the Check the steering cylinder mounting points and steering cylinder mounting lubricate repair as necessary points There is binding in the drive Check the drive yoke weldment bearing cups bearing yoke weldment bearing cups cones and drive yoke pivot pin and lubricate repair as bearing cones or drive yoke necessary pivot pin Specifications Steering Rear wheel hydraulic cylinder and rotary valve controlled P 1 813 psi 125 bar Maximum Pressure T 290 psi 20 bar on Connections H and L 2 610 psi 180 bar Steering Control Unit Recommended Oil Flow 1 9 5 3 GPM 7 20 LPM Displacement 4 88 CIR 80 cm Rev Check Valve for Manual Steering Yes Relief Valve 1100 psi 75 8 bar Nilfisk s Advance Service Manual SW8000 Sweep System Main Broom Functional Description The hydraulically powered main broom 1 used to sweep dry debris into the
119. esistance solenoid valve is not doesn t measure approximately 9 ohms 10 operating replace the coil e Check the function of the solenoid valve cartridge Replace as necessary The S2 Main Broom solenoid valve is stuck open The S6 Hopper Up Bypass Check the function of the solenoid valve cartridge solenoid valve is stuck closed Replace as necessary The S5 Hopper Up Down solenoid valve is stuck open The hopper door The Open Dump Door Switch Check the connection between the touch pad switch doesn t open when is not making connection panel and pin J3 5 on the A2 Main Machine Controller the Open Dump Door with the A2 Main Machine If the connection is OK there may be a problem with Switch is pressed Controller the touch pad switch panel or the A2 Main Machine Controller There is no power to the S7 Check the wiring to the S7 Hopper Open solenoid Hopper Open solenoid valve valve The solenoid receives positive battery voltage and is grounded to the A2 Main Machine Controller when the Lower Hopper Switch is pressed Repair replace the wiring as necessary The S7 Hopper Open solenoid Check the solenoid coil resistance If the resistance valve is not operating doesn t measure approximately 9 ohms 10 replace the coil e Check the function of the solenoid valve cartridge Replace as necessary There is binding in the hopper Check for any mechanical binding or damage to the door mount or hopper door ho
120. ey enter the sealed back of the module 4 Check the continuity of the five wires going to the Valve Assembly VIO WHT GRN GRA BLK WHT and ORN is continuity all five wires from the cab to the Valve Assembly continue to step 5 is no continuity in any of the five wires from the cab to the Valve Assembly you will need to either repair the wires or run new wires to the Valve Assembly 5 Install the replacement Heater Temperature Control on the Overhead Control Plate 6 Splice the original wires from the Valve Assembly to the replacement Heater Temperature Control using butt connectors and heat shrink insulation 7 Reinstall the Overhead Control Plate in the cab 159 Service Manual SW8000 Options and Accessories 160 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 1s the fact that the heater cores 1n 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 1s 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 remov
121. f hydraulic oil the piston pump sends to the drive motor This determines the machine speed The Foot Pedal actuates the Lever Weldment Push Pull Control Cable which actuates the Hydroback The Rod End on the Throttle Hydroback pivots the Lever and attached Lever Weldment Plate connected to the piston pump control shaft to control the oil direction and flow volume from the pump to the drive motor The Hydroback returns the Lever Weldment piston pump control shaft and Foot Pedal to the neutral position when the Foot Pedal is released The Cam Push Pull Control Cable is connected to the hopper and the Nylon Cam When the hopper is raised the Cam Push Pull Control Cable rotates the Nylon Cam to limit the rotation of the Lever Weldment This restricts the machine travel speed when the hopper 1s raised Weldment The Rotary Sensor referred to as the Drive Pedal Sensor Rotar 5K Ohm in the electrical ladder diagram is coupled to EM the Lever Weldment Rotary Sensor must be in its deadband range before the engine can be started Refer to the Hydrostatic Neutral Position and Dead band section for instructions on how to set the Rotary Sensor i Connected to Hopper Connected to Foot Pedal Weldment Push Pull Control Cable 199 Service Manual SW8000 Wheel System Traction 200 Rear Wheel Assembly The Rear Wheel Assembly is bolted to the Drive Wheel
122. fers 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 to the A C Compressor to complete the refrigeration cycle The Operator moderates the cab cooling by mixing in heated air from the heater core in the Evaporator Heater Unit by adjusting the Heater Temperature Control 4 The Thermostat 833 normally closed has a temperature probe that is inserted into the evaporator coil in the Evaporator Heater Unit When the temperature of the evaporator coil reaches 39 5 F the Thermostat closes to enable the A C system When the temperature of the evaporator coil drops to 31 F the Thermostat opens to switch off the A C system The Binary Pressure Switch 834 19 normally closed located on top of the A C Receiver Dryer will interrupt the 12 VDC to the Compressor Motor Hydraulic Valve L10 29 to switch off the Hydraulic Compressor Motor and A C Compressor under the following two conditions The refrigerant line pressure drops below 30 psig indicating an insufficient amount of refrigerant 1n the system The refrigerant line pressure rises above 270 psig indicating an overheated or unsafe co
123. fittings as described below it s M fitting on the longest line 13 If necessary slightly loosen one of the four Injector Fittings 14 Crank the engine to bleed any air from the Injector Fitting 15 When the injection pulses can be seen at the Injector Fitting and the fuel 1s running clear tighten the Injector Fitting 16 Repeat steps 13 through 15 above for the other three Injector Fittings 17 Make sure the check valve 1s oriented so that fuel can only flow from the rear injector to the fuel tank 220 Injecto Service Manual SW8000 Engine System Diesel 88 Troubleshooting BA Note Also refer to the Workshop Manual Diesel Engine 05 Series WG1605 9Y111 06610 pdf for et additional troubleshooting information and procedures General Troubleshooting Problem Correction The engine will not The drive pedal is not in Make sure the drive pedal is in its neutral position crank the starter does neutral not engage The battery charge level is 1 Check the battery voltage and charge as necessary low 2 1 the engine still won t crank load test the battery Replace the battery if necessary No power to the starter Check circuit breaker CB1 and reset if necessary Check circuit breaker CB3 and reset if necessary Make sure there is continuity through the Neutral Relay K4 terminals 30 and 87a with the drive pedal in neutral 1 Reset the foot pedal deadband position if necessary Refer to
124. g Switches Know Your Machine Nilfisk Iu f Advance Service Manual SW8000 30 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 Control Panel The control panel display is an integral component with the Main Machine Controller A2 circuit board Horn Switch Fuel Gauge Propane Low Indicator Check Engine Indicator Glowplug Indicator Diesel Only Headlight Switch Engine Speed Switch Side Broom Switch Dust Control Switch Shaker Switch Raise Hopper Switch Open Dump Door Switch Hopper Up Indicator 2 Hopper Over Temp Indicator e Close Dump Door Switch Key Switch Hour Meter Check Engine Indicator Lower Hopper Switch Service Manual SW8000 Control System 31 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
125. ge the slots in the broom drive hub and that the broom is fully seated 8 Swing the idler arm back into the broom core Make sure the lugs on the idler arm engage the slots in the broom core 9 Close and latch the broom access panel Service Manual SW8000 Sweep System Broom 187 Inspect and Adjust the Broom Height The main broom has 2 operating positions Float 7 and Sweep 6 In the Float position the height 1s left uncontrolled floating and the pressure on the broom 1s 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 1s 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 1s 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 Leave the engine running 3 Move the Main Broom Lever 5 forward to the Sweep position 6 4 Without actually moving the machine lightly press the drive pedal out of the neutral position just enough to engage the broom This allows the broom to polish a strip on
126. he 2 9 5 7 gpm splitter is a 2 1 ratio splitter at any flow rate When the main broom is on the Main Broom solenoid valve 52 1 active fluid can flow through and the Bypass solenoid S6 is active blocking fluid Hydraulic fluid flows through the Main Broom motor and through the Dust Control system The dust control system contains a bypass valve so that fluid will always be available to flow regardless whether the vacuum motor 1 active or not The Main Broom motor contains a case drain The case drain is not normally part of the hydraulic circuit but 1t permits excess and leakage hydraulic fluid to return to the sump and prevents damage to the motor case 1n the event that the motor s case were to become pressurized 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 Idler Arm Main Broom Switch Broom Motor Main Broom 185 Service Manual SW8000 Sweep System Main Broom 186 Maintenance and Adjustment When the machine 1s not 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 re
127. he brooms The DustGuard solenoid valve opens to allow water flow from the misting pump to the nozzles when the power to the misting pump switches removable Strainer is installed the water line upstream of the misting pump and solenoid valve Removable strainers are also located inside of the nozzle assemblies When installed and the manual switch 1s activated the DustGuard spray system will turn on automatically when the side broom 1s turned on Dust Control Vacuum System The hydraulically driven impeller is mounted in the side wall of the hopper and pulls air from the hopper through the filter and discharges 1t out the rear of the machine An optional clogged filter sensor switch will shut off the vacuum motor if the vacuum on the clean side of the filter gets too high as a result of a clogged filter When the switch 1s activated the LCD will display an 1con to the operator The filter system contains a shaker motor that vibrates the filter to shake loose particulate from the bottom of the filter to assist in keeping the filter clean When the shaker switch is pressed the vacuum motor turns off and the shaker motor turns on The shaker motor contains an eccentric weight that causes vibration when rotated This reduces filter maintenance and helps maintain adequate airflow through the filter The filter shaker will automatically switch on for a short period when the sweep system 1s turned off broom raised Circuit Description
128. heck for the heated coolant being switched on and off to the heater core Motor Pin Note that it will take approximately 15 20 seconds for the valve motor to run Motor Pin between its full off and full on positions Feedback Pin Ifthe valve motor isn t running w replace the Valve Assembly Feedback Pot Pin mend w If the valve motor appears to be running correctly continue on to step Feedback Pin 5 below i 1 4 Checkthe resistance through the Figure 6 Valve Assembly Connector Pins Feedback Pins to determine if the feedback potentiometer the Valve Assembly 1s working correctly The resistance values should be close to those shown 1n the table below Ohmmeter Connections Resistance Approximate Valve Open to Heater Core Feedback Pin and Feedback Pin 5 71kQ Heater Temperature Control set to Hot full clockwise Feedback Pin and Feedback Pot Pin 5 55 Feedback Pot Pin and Feedback Pin 0 88 Feedback Pin and Feedback Pin Valve Closed to Heater Core Heater Temperature Control set Feedback Pin and Feedback Pot Pin to Cold full counterclockwise Feedback Pot Pin and Feedback Pin Feedback Pin and Feedback Pin 5 71 Valve Halfway Open Heater Temperature Control set to Feedback Pin and Feedback Pot Pin 3 14kQ approximate midpoint Feedback Pot Pin and Feedback Pin 3 25 kQ 5 Ifthe Feedback Pin
129. her the accessory or ignition position to provide 12 VDC GRN BLU wire to the 20A circuit breaker CB4 Circuit breaker 4 must be closed to provide 12 VDC VIO wire to the control side coil of the HVAC Relay K8 The 20 circuit breaker CB9 must be closed to provide voltage RED VIO wire to the load side of the HVAC Relay K8 HVAC Relay K8 must be closed to provide 12 VDC VIO GRA wire to the positive terminal on the Fan Switch S30 The Fan Switch 30 must be set to the Low Medium or High position to provide 12 VDC RED WHT wire to the AC Switch 535 The AC Switch 535 must be closed to provide 12 VDC to The control side coil of the Condenser Fan Relay K9 WHT wire The input terminal on the Thermostat 33 BLK WHT wire The Thermostat 33 normally closed must be closed to provide 12 VDC GRN wire to the input terminal on the Pressure Switch 594 The Binary Pressure Switch 34 normally closed must be closed to provide 12 VDC GRN WHT wire to the load side of the Compressor Relay K10 terminal 30 The load side of the Compressor Relay K10 normally closed must be closed to provide 12 VDC BLU BRN wire from terminal 87a to the Compressor Hydraulic Valve L10 Down Hydraulic Valve L5 When the Raise Hopper switch is pressed it actuates the Hopper Up Down Hydraulic Valve L5 to raise the hopper and actuates the Compressor Relay K10 coil to open the circuit to the Compressor Hydraulic Valve 1 10 and switch
130. 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 The main broom 1s activated lowered and spinning when the control panel energizes the 52 Main Broom Enable valve The control panel will energize the 52 solenoid only when the following conditions are met The engine 1s running with the Engine Speed Switch set to full throttle The hopper is properly seated The 54 Hopper Interlock switch is closed to ground to indicate the hopper 1s properly seated The Main Broom Lever is in the Sweep Down or Full Float position The Drive Pedal is activated The electrical and hydraulic circuitry related to the main broom is shown in the following simplified diagram and explained on the following page BATTERY 12 Vdc CB1 CIRCUIT BREAKER 70 AMP STARTER COMMAND START ENGINE SYSTEM CSN IGN SW INPUT SWITCH IGN CB4 ACC Closed when hopper is down CIRCUIT BREAKER 20 AMP A2 CONTROL BOX ASSEMBLY Closed when filter is plugged Open when broom is down VALVE 52 BROOM High Pressure nnn SWITCH DUST CONTROL FILTER OPTIONAL SWITCH MAIN BROOM gt 3 Main Broom Side Broom XI Control 1
131. il cooler tips out for easy cleaning gt Engine Oil Gasoline Petrol amp Lpg Check the engine oil level when the machine is parked on a level surface and the engine is cool Change the engine oil after the first 35 hours of operation and every 150 hours after that Engine oil should have properties of API classification SL or higher and suited to seasonal temperatures Refer to the Kubota Workshop Manual Engine Specifications and Operator s Manual for the WG1605 for further information Replace the oil filter with every oil change Temperature Range Oil Weight Above 25 C 77 F or SAE10W 30 SAE15W 40 0 C to 25 C 32 F to 77 F SAE20 or SAE10W 30 0 C to 20 C 32 F to 4 F SAE10W or SAE10W 30 Engine Oil Diesel Check the engine oil level when the machine 1s parked on a level surface and the engine 1s cool Change the engine oil after the first 35 hours of operation and every 150 hours after that Use CF CF 4 or CG 4 oil meeting API specifications and suited temperatures important reference the oil fuel type note below for further diesel oil recommendations Refer to the Engine System section for oil capacities and additional engine specifications Replace the oil filter with every oil change Temperature Range Oil Weight Above 77 F 25 SAE 30 or SAE 10W 30 SAE 10W 40 32 F to 77 F 0 C to 25 C SAE 20 or SAE 10W 30 SAE 10W 40 Below 32 F 0 C SAE 10W or SAE 10W 30 SAE 10W 40 Diesel Lu
132. in the corresponding direction The swash plate in the Piston Pump regulates the direction and volume of oil the Piston Pump sends to the Drive Motor to control the machine direction and speed The direction 1n which the foot pedal moves the swash plate 1n the Piston Pump controls the machine direction The distance to which the foot pedal moves the swash plate the Piston Pump controls the machine speed The return oil from the from the Oil Cooler and Filter passes through the appropriate Check Valve to provide make up oil to the return slack side of the Piston Pump When the return oil pressure from the Oil Cooler and Filter exceeds 100 psi the 100 PSI piloted relief valve opens to allow the return oil to flow to the Reservoir The case drain from the Piston Pump goes to the Reservoir Wheel System Traction 202 From Oil Cooler and Filter From Oil Cooler and Filter Check Valve Reservoir Service Manual SW8000 Drive Motor Stalling Out If the Drive Motor is unable to run in forward or reverse for any reason rear wheel stalled etc the corresponding internal 3000 PSI relief valve in the Piston Pump will open to bypass the Drive Motor to prevent damage to the hydraulic components Wheel System Traction 203 From Oil Cooler and Filter 5 A Reservoir Service Manual SW8000 Wheel System Traction 204 Component Locations The fo
133. ine 15 Technical Specifications s ee ee aw eb o ook om OX 25 16 Fastener Torque Specifications 18 Maintenance saaa a 19 Maintenance 5 19 4 aa gb oe 5 66 GREG 19 To Shut Down The Diesel Gasoline Engine 1 1 20 To Shut Down The Propane Engine 20 Important Machine Lubrication 20 20 Engine Oil Gasoline Petrol amp 100 4 6 XO 21 Diesels 2325 eee ERES 666886 21 Xx 22 Engine Maintenance 150 22 OU 22 Hopper Dust Control Filter Panel 23 To remove the hopper dust control filter eee 23 23 23 23 SW8000 PM Checklist moan pees bo eR he AE EE Eee eee eae wee hehe a ee 24 Know Your 26 Operator s 28 CORTO PONG P Bw A UE dE d 29 Control System 30 Functional
134. ine and out through the radiator Service Manual SW8000 Engine System Diesel 76 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 e Workshop Manual Diesel Engine 05 Series WG1605 9Y111 06610 pdf Woodward Product Specification 03399 APECS 0175 Series Actuators Engine Starter Circuit Battery 12 VDC 2 CB1 Circuit Breaker 70 Amp F BLU PINK 1 oo c Ww 2 IIl Circuit Breaker Main Machine 15 Neutral Relay Controller O closed in neutral Starter RED Ignition Switch Drive Pedal Sensor Bt 5K Ohm Starter Circuit Description For the engine to start The Ignition Switch must provide positive voltage to the contact side of the Neutral Relay K4 and to the positive terminal on the Starter The A2 Main Machine Controller must send power to the coil on the Neutral Relay K4 In order to do this the A2 Main Machine Controller must sense that the resistance through the 5K Ohm Drive Pedal Sensor is within the programmed deadband range The Neutral Relay K4 must close to provide positive voltage to the Starter Service Manual SW8000 Engine System Diesel 77 Engine Protection Low Oil Pressure Shutdown Battery 12 VDC t li 2 CB1 Circuit Breaker 70 Amp 7 Ignition Switch CB
135. ions Machines used in severe operational environments may require service more often Maintenance Item Perform the After Use maintenance steps Check parking brake Clean main and side broom s Check filter indicator and lights hyd amp air Check engine coolant level Check hydraulic oil level Maintenance Item Rotate main broom Clean the DustGuard Spray Nozzles amp Strainer Inspect adjust brooms Check Clean Hopper Dust Control Filter Using Method A Inspect broom housing skirts Inspect hopper seals Clean radiator and oil cooler Perform engine maintenance Inspect and grease steering spindle Check Clean Hopper Dust Control Filter Using Method Check Clean Hopper Dust Control Filter Using Method C Change the hydraulic oil filter Change reservoir hydraulic oil Flush the radiator Engine fuel filter s 15 hrs X X 30 hrs gt lt X Perform Daily X X lt X 150 hrs 300 hrs 1000 hrs X X X X X X X X See the Mechanical Repair Service Manual for detailed maintenance information of systems listed Sweeping Hopper Steering Dust Control NOTE Cleaning the hopper dust control filter is not required on models using the maintenance free bag filter After Use 1 Shake the Hopper Dust Control Filter Figure 6 12 and empty the hopper 2 Check the maintenance schedule and perform all required maintenance before
136. ith an ECom communication cable See the Diagnosis Manual ECM System WG1605 9Y110 01760 pdf for the diagnostic tool connection procedure The ECom cable can be purchased through Nilfisk Advance See Special Tools in this section for the part number It is the same cable that has been used on other recent Nilfisk Advance machines using the GM 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 MA Note Refer to the Diagnosis Manual ECM System WG1605 9Y110 01760 pdf for engine troubleshooting information and procedures including all fault code diagnosis General Troubleshooting Problem Correction The engine will not Weak battery poor battery Check the battery and connections and clean repair crank cable connections as necessary Check the wiring from the battery to the Starter B terminal on the Engine System and repair as necessary No power to the Starter Make sure the foot pedal is in the neutral position Solenoid Starter Command Reset the foot pedal deadba
137. k under the hopper without first engaging the Prop Rod To engage the Prop Rod 1 Raise the hopper to its full up position 2 Pull the Hopper Safety Support Handle toward the rear of the machine to retract the Prop Rod to the engage position as shown in the adjacent photo 3 Lower the hopper to engage the Prop Rod To disengage the Prop Rod 1 Raise the hopper to its full up Hopper Safety position Support Handle 2 Push the Hopper Safety Support Handle toward the front of the machine to extend the Prop Rod to the disengage position 3 Lower the hopper Hopper System 122 Service Manual SW8000 Hopper System Hopper Door Cylinder The Hopper Door Cylinder is attached to the Hopper Door and Hopper Lift Arm Weldment and retracts and extends to open and close the Hopper Door Hydraulic Manifold Assembly and Solenoid Valves The Hydraulic Manifold Assembly is mounted on the frame underneath the center cover assembly DustGuard tank 54 Only The S5 Hopper Up Down S7 Hopper Installed on Open and S9 Hopper Lower solenoid valves are mounted on the top of the Hydraulic Manifold Assembly Litter Vac Kit The S6 Hopper Up Bypass and S1 Hopper Close Open solenoid valves are mounted ES a z d on the bottom of the Hydraulic Manifold Oe SUL Hydraulic Manifold Assembly Assembly A 28 56 Hopper 1 V s UP Bypass E S1 Hopper Close Open N
138. k valve C1 1s active and this allows fluid to pass backward through the check valve to drain excess fluid from the second optional lift cylinder Excess fluid from the first lift cylinder flows through the inactive 53 valve to return to the sump In the event that the main broom 1s running without the side brooms the 3 valve also contains a side broom bypass circuit to permit excess fluid not needed by the main broom to return to the low pressure return line Side Broom Lift High Pressure Low Pressure Side Brooms Raised Motors Inactive gt gt gt gt gt gt gt gt Pilot Control Sump Return gt Flow Direction Side Broom Lift t 1 Pilot Controlled Check Valve Side Broom Dual Broom Option A w o Pressure K w Pressure Speed Control Slave to 3 Side Broom To Steering i 52 Flow Spliter Ei Pressure Relief Hopper Up Sweep Bypass 4 4 4 4 6 4 4 4 lt 4 4 lt 4 l Y Y Sump Y Service Manual SW8000 Sweep System Side Broom 192 Hydraulic Circuit Brooms On In order for the side brooms to operate the main broom must be running The 52 solenoid 1s energized to allow fluid to flow to the splitter between the main broom and the side broom circuits The side broom so
139. l the steering wheel shaft rotates the Rotary Valve and Rotary Meter which are connected by a mechanical link inside of the Steering Control Unit The direction in which the Rotary Valve moves determines which side of the Steering Cylinder receives the hydraulic oil to turn the drive wheel left or right Note that when the Operator stops turning the steering wheel the springs in the Steering Control Unit return the Rotary Valve to the neutral closed position to hold the Steering Cylinder rod in its current position The number of degrees that the Rotary Meter rotates determines the volume of oil that the Steering Cylinder receives from the Rotary Valve This allows the drive wheel to turn proportion to the steering wheel rotation Steering Cylinder Stationary C p L R Rotary 4 7 Valve fol Steering ES ry U Rotary Meter Oil to Cooler Filter and Reservoir Oil from A Port on Hydraulic Manifold Service Manual SW8000 Steering Wheel Stationary When the engine 1s running the Gear Pump sends oil through the 2 0 GPM flow divider in the Hydraulic Manifold Assembly to the A port on the Steering Control Unit When the steering wheel is stationary the Rotary Valve is in its neutral closed position The hydraulic oil flows through the U shaped ports in the Rotary Valve through the T port on the Steering Control Unit then to the Oil Cooler and Fi
140. lenoid 33 1s 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 Brooms Lowered Motors Active Pilot Control Sump Return Flow Direction Pilot Controlled Check Valve bh w o Pressure Side Broom Dual Broom YN Flow Speed w Pressure Control i d d 4 Side Broom To Steering Flow Spliter Pressure Relief Hopper Up Sweep Bypass Service Manual SW8000 Sweep System Side Broom 193 Component Locations The diagram below shows the location of the side broom motor lift cylinder and hydraulic valves Hydraulic Valves Side Broom TN TT DUM Side Broom Motor Lift Cylinder Ser
141. lenoid valve S9 The hydraulic oil is directed through the de energized Hopper Up Bypass solenoid valve S6 then to the retract upper port M on the Hopper Lift Cylinder to lower the hopper The check valves in the de energized Hopper Up Down solenoid valve S5 block the oil to and from the extend lower port N on the Hopper Lift Cylinder The hydraulic oil also deadheads at the check valve in the de energized Main Broom solenoid valve S2 and at the Captive Plug in the pressure line The oil from the extend lower port N on the Hopper Lift Cylinder goes through the energized Hopper Lower solenoid valve S9 then returns to the Reservoir Service Manual SW8000 Hopper System 119 Open Hopper Door Hopper Dump Cylinder Opens Hopper Door gt _ a i From Steering Steering 24419 Cose open To Oil Cooler and Filter T m m m m m m m 1 2400 C RPM 1 02 CIR Reservoir 2 Note The hopper door only be opened and closed manually when the hopper is not down ne The hopper door opens automatically when the hopper is down and the main broom is on When the Open Dump Door Switch on the control panel is pressed the A2 Main Machine Controller energizes the Hopper Close Open solenoid valve 1 The hydraulic oil goes through the de energized Hopper Open solenoid v
142. lics Yes There is no cold air from the Evaporator Heater Unit Is there 12V across the coil on the Compressor Hydraulic Valve L10 hopper down A C switched on Is there 12V at the WHT wire on A C Switch S35 ref to bat neg w A C Switch S35 on Yes Is there 12V at the GRN wire on the Thermostat S33 ref to bat neg Yes Is there 12V at the GRN WHT wire on the Pressure Switch S34 ref to bat neg Yes Is there 12V at the BLU BRN wire on the Compressor Relay K10 ref to bat neg with the Hopper down Yes Is the hydraulic pressure at the auxiliary pump test port within specs Check the compressor and air Yes gt conditioning system components 4 Note Refer to the Cab Electrical Wiring and Ladder Diagrams in Appendix and the Component Troubleshooting subsections on the following pages 164 Service Manual SW8000 Options and Accessories 165 Component Troubleshooting Compressor Motor Hydraulic Valve L10 Refer to Figure 8 MA 7 Note The Compressor Motor Hydraulic Valve and Hydraulic Pressure Test Port are attached to n 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 Ifthere is 12 VDC at the Electrical Connector and the c
143. ller neck as viewed when the Filler Cap 1s removed Filter The Oil Filter is mounted to the machine frame and filters the oil returning to the reservoir E Filler E Hydraulic Oil Lm Reservoir Hydraulic System 131 Service Manual SW8000 Hydraulic System 132 Oil Cooler The Oil Cooler is mounted to the rear of the engine Radiator 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 To Check the Hydraulic Oil Level Remove the filler cap from the reservoir and check the hydraulic oil level in the reservoir The hydraulic oil level should be halfway up the Filter Screen inside the reservoir filler neck Add 10w 30 oil as needed Note Change and flush the oil if major l g fl f maj contamination from a mechanical failure occurs Service Manual SW8000 Hydraulic System 133 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 1 It s recommended that you lay down some rags or paper towels underneath the Oil Filter to catch any oil that may spill I
144. llowing components are included in this section Piston drive Pump and Tow Valve Drive Motor and Rear Wheel Assembly Foot Pedal Assembly e Forward Reverse Controls Piston drive Pump and Tow Valve The Piston Pump blue 1s attached to the front end of the engine The Tow Valve is mounted onto the Piston Pump Drive Motor and Rear Wheel Assembly The Drive Motor and Rear Wheel Assembly are mounted to the Drive Yoke Weldment Dive Yoke Weldment Service Manual SW8000 Wheel System Traction 205 Foot Pedal Assembly The Foot Pedal Assembly actuates the forward reverse controls to control machine direction and speed Foot Pedal Assembly Forward Reverse Controls The lever weldment push pull control cable Lever Weldment Lever Nylon Cam and Hydroback are mounted on the left side of the machine underneath the center E Oy cover assembly DustGuard tank 5 3 27 Bracket esu e e eia The Rotary Sensor is coupled to the Lever NT si Weldment and is mounted to the jii Sensor Bracket Service Manual SW8000 Wheel System Traction 206 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 AY Not
145. lter Note that when the steering wheel 1 stationary the Rotary Valve ports are blocked and the Steering Cylinder will maintain its current position To Oil Cooler and Filter 2400 RPM Steering System 175 Steering Cylinder Stationary L R Rotary 4 Valve wal e Rotary o Meter Hydraulic Manifold Assembly Reservoir Service Manual SW8000 Steering Wheel Turned Toward the Right When the Operator turns the steering wheel to the right the Rotary Valve directs the hydraulic oil to the corresponding side of the Rotary Meter The Rotary Meter sends the appropriate volume of oil to the Steering Cylinder corresponding to the amount of steering wheel rotation To Oil Cooler EE L Steering System 176 Steering Cylinder Moves Drive Wheel to Steer Machine Toward the Right R Rotary Valve M o Rotary Meter T um uw Pl 2 sr Hydraulic Manifold Pump Assembly CIR Reservoir Service Manual SW8000 Steering Wheel Turned Toward the Left When the Operator turns the steering wheel to the left the Rotary Valve directs the hydraulic oil to the opposite side of the Rotary Meter The Rotary Meter again sends the appropriate volume of oil to the Steering Cylinder corresponding to the amount of steering wheel rotation To Oil Cooler and Filte
146. ludes the Steering Wheel Steering Control Unit Steering Cylinder and Drive Yoke Weldment The Steering Wheel rotates the shaft on the Steering Control Unit which controls the oil flow to the Steering Cylinder The Steering Cylinder extends and retracts to rotate Drive Yoke Weldment to steer the Rear Wheel Assembly 172 Steering Control oteering Unit Wheel Steering Cylinder Yoke Weldment Rear Wheel Assembly Service Manual SW8000 The A port on the Hydraulic Manifold Assembly supplies hydraulic oil to the P pressure port on the Steering Control Unit The oil from the T tank port on the Steering Control Unit goes to the T1 port on the Hydraulic Manifold Assembly then to the oil cooler filter and reservoir The Steering Cylinder is connected to the and L ports on the Steering Control Unit When the Operator turns the steering wheel the Steering Control Unit directs the oil to the or L port on the Steering Cylinder to steer the machine right or left Hydraulic Manifold Assembly Steering Cylinder Steering Control Steering System 173 Service Manual SW8000 Hydraulic Diagrams Steering Control Unit Description Steering System 174 The Steering Control Unit uses the input from the steering wheel to turn the drive wheel in the appropriate direction to steer the machine When the Operator turns the steering whee
147. ly Line m a P ar mm 3 yt _ iz B 3 1 80 Amr gt i Air Switch Venturi Tube Assembly Filling Cooling System with Coolant Coolant Valve closed Coolant Supply Line Service Manual SW8000 Engine System Diesel 84 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 The inner safety element blue should be replaced every third time that the primary filter element is replaced Never attempt to clean the inner safety element To clean the primary filter element 1 Unlatch the two Clips at the end of the Air Filter and remove the End Housing mg End P Housing EMI 2 Pullthe primary element out 3 Clean the element with compressed air maximum pressure 100 psi or wash it with water maximum pressure 40 psi Do not put the element back into the canister until it is completely dry 4 Reinstall the inner safety element and primary filter element 5 Reinstall the End Housing and latch the two Clips e aM Clip B Replacing the Fuel Filter surrounding areas This can present a potential fire ha
148. m Xd Rea 3 181 Troublesho ting 182 5 182 Service Manual SW8000 Sweep System Main 183 Functional Description ooa 183 Circuit hee he Roe ee EX wu E 183 HyVaraunc Opera UON 184 Component Locat ns e s s sds ss E OR YOOX 185 Maintenance and 186 Cleaning and Inspecting the Main 186 Rotate or Replace the Main Broom 186 Inspect and Adjust the Broom 187 Inspect SKII S eee EEEE AGES HG 8 225 40 eae 187 Troubleshooting x oe x xu Cee ee E OR ER EROR UP STE UR ee 4 188 Main Broom Motor Will Not 188 5 189 Sweep System Side 190 lt 190 190 191 Hydraulic Circuit Brooms Off 191 Hydraulic Circuit lt 192 Component 5 193 Trouble
149. mperature control 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 input load side of the HVAC Relay K8 HVAC Relay K8 must be closed to provide 12 VDC VIO GRAY to RED wire to the Heater Temperature Control E1 Negative Voltage The Heater Temperature Control 1 BLK wire must be connected to battery ground The control side coil of the HVAC Relay K8 must be connected to battery negative BLK wire Service Manual SW8000 Electrical Troubleshooting Options and Accessories 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 12V at the VIO GRA wire on the Fan Switch S30 ref to bat neg w key switch on Yes Reset or replace circuit breaker CBA Is there continuity through 20 circuit breaker CB4 Reset or replace circuit breaker CB9 Is there continuity through 20A circuit breaker CB9 Does the resistance of Relay coil K8 measure 850 420 Replace the No Relay Is there continuity through the load Replace the No contacts o
150. ms nominal Check wiring for a short circuit Brn 24 Jt 8 Dust control bypass solenoid L8 overload e Check coil resistance If below 6 Ohms replace 8 3 1 J1 9 Hopper lower solenoid L9 overload ohms nominal e Check wiring for a short circuit Yel Grn e Check coil resistance If below 70 Ohms replace 85 Shaker relay K3 overload ohms nominal Check wiring for a short circuit Yel Red 01 15 Back up alarm overload Check wiring for a short circuit Grn Brn f overload persists replace the alarm e Check coil resistance t If below 70 Ohms replace 85 J1 16 Light relay K2 overload ohms nominal e Check wiring for a short circuit Yel Wht e Check coil resistance t If below 70 Ohms replace 85 4 1 J1 18 Neutral start relay K4 overload ohms nominal Check wiring for a short circuit Gry Wht e Check coil resistance t If below 70 Ohms replace 85 Horn relay K1 overload 4 2 J1 19 ohms nominal Coil spec is 85 Ohms e Check wiring for a short circuit Vio Brn Engine speed output overload Throttle input to engine ECM A3 is OV for idle and 4 3 J1 17 Note the Gra Blu wire is 0 V s when 12 for high speed engine is 9 idle Check Gra Blu wire for a short to ground opare overload 1 When testing for short circuits make sure the machine 1 off and disconnect the connectors at the solenoid or relay in question and also at the main controller Then use an ohmme
151. n K8 relay terminals 30 and 87 when the coil is energized Check the connectors and wiring and repair as necessary Is there voltage at each of the three positive terminals on Fan Switch S30 when N Replace the Fan the Switch is set to the gt Switch 580 corresponding fan speed YEL RED and ORN wires ref to bat neg Is there continuity in the YEL RED and ORN wires from Fan Switch 30 to the Repair the positive terminals on the wires Blower Motor M6 Is there 12V in the BLK wire from the negative terminal on the Blower No gt Repair the Motor M6 ref to bat pos wire Replace the Blower Motor M6 157 Service Manual SW8000 Options and Accessories 158 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 1s at the recommended level and there are no air locks the cooling system Refer to the To Eliminate Air Locks from the Cooling System subsection To Troubleshoot the Valve Assembly the Valve Assembly 1 Disconnect the electrical connector from xi J 2 Carefully connect a 12 VDC source to the Motor and Motor pins directly or via the BLK WHT and ORN wires in the connector to run the butterfly valve motor independently without input from the heater temperature control 3 C
152. nd Connector Rail Connector Nuts CT c uw P ol gt n 5 Insulate the Electric Terminal that feeds the rail to prevent it from shorting to ground 6 Clean the area around the glow plugs to prevent any debris from falling into the engine cylinders when they are removed 7 Remove the glow plugs U Electrical Terminal 4 Service Manual SW8000 Engine System Diesel 91 8 To test the compression of one of the cylinders screw in an appropriate adapter into the glow plug threads 1n the cylinder head and attach a suitable compression gauge Pictured are Snap On Diesel Compression gauge EEPD500 used with compression test adapter fitting TU 15 35 and coupler M3569 EEPD500 p 5 Snap On A m3569 49 m b Snap On 9 Disconnect the Injector Pump Actuator Connector to prevent the engine from starting 10 Remove any cover over the air inlet but be very careful not to allow anything to get sucked 1n during the test 11 Crank the engine over until the compression gauge stops climbing Record the reading The cranking compression specifications are shown in the following table M Injector Pump Actuator Connector Specification Allowable Limit The allowable difference among cylinders is 10 or less 12 R
153. nd position if necessary circuit Refer to the Control System Main Machine Controller Programming section Make sure there is continuity through the Neutral Relay K4 contacts 30 and 87a relay off Check the starter relay operation Check circuit breaker CB1 and reset if necessary Check circuit breaker CB3 and reset if necessary Service Manual SW8000 Engine System Gasoline LPG 107 Problem Cause Correction The engine will not No power to the Ign Switch e Check circuit breaker CB5 and reset if necessary start Input terminal on the A3 e Check the continuity from the Ignition Switch to the Engine System Ign Switch Input terminal the Engine System and repair as necessary Engine will not runat Loss of throttle input from Check that a voltage signal is being sent to the high speed Main Machine Controller to engine controller when the Throttle Switch is set to Engine Controller operating speed Engine System Problem Refer to Diagnosis Manual ECM System WG1605 9Y110 01760 pdf The engine stops The coolant temperature is too Refer to the Engine Overheating Problems section running check engine high below light is on The oil pressure has dropped Refer to the Loss of Oil Pressure Protection section too low below Engine Management System Consult Diagnosis Manual ECM System WG1605 Problem 9Y110 01760 pdf Engine Overheating Problems Use the checklist below as a guide to thoroughly check th
154. ndition The Compressor Relay K10 80 will interrupt the 12 VDC to the Compressor Motor Hydraulic Valve L10 to switch off the Hydraulic Compressor Motor and A C Compressor whenever the hopper is raised Electrical Circuit Overview Blower Motors The following conditions must be met for the blower motors 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 The HVAC Relay K8 must be closed to provide 12 VDC VIO GRAY wire to the positive terminal on the Fan Switch 530 The Fan Switch 30 must be set to the Low YEL wire Medium RED wire or High ORN wire position to provide 12 VDC to the corresponding terminals on the Blower Motors 9 and M10 Negative Voltage The Blower Motors M9 and M10 must be connected to battery negative BLK wires The control side coil of the HVAC Relay K8 must be connected to battery negative BLK wire Service Manual SW8000 Options and Accessories 162 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 eit
155. ne through the gas filter to the Gasoline Fuel Pressure Manifold assembly The Gasoline Fuel Pressure Manifold assembly controls the delivery of gasoline to the gasoline injector rail assembly Each cylinder has fuel rail mounted with injectors An Electronic Throttle Body ETB 1 used to control engine speed The Gasoline Fuel Pressure Manifold 1s equipped with a sensor that sends fuel temperature and pressure data to the Engine Control Module The ECM uses this information to calculate the precise amount of gasoline to be injected to the engine during operation This eliminates the need for a separate return line from the fuel rail assembly Kubota 1 6L LPG Fuel System Description The fuel system on LPG engines includes an LPG Fuel Lock off device Dual Stage Regulator DSR Direct Electronic Pressure Regulator DEPR Mixer Assembly and Electronic Throttle Body An LPG Fuel Lock off device consisting of a 12 volt solenoid and a normally closed valve opens during cranking and engine run cycles The ECM controls the voltage to the LPG Fuel Lock off device The DSR is a two stage regulator that is a combination vaporizer pressure regulating device The DSR normally closed when the engine is not running When the engine is cranking or running a partial vacuum is created in the fuel line which connects the regulator to the DEPR and Mixer Assembly This partial vacuum opens the second stage regulator permitting fuel to flow
156. nector ID Component to Connector ID Look up Table A2 Main Machine Controller Service Manual SW8000 Component to Relay ID Look up Table Horn Relay K1 Seat Relay 0 5 Second Delay Relay Connector Pin out Assignments Connector J1 A2 Main Machine Controller Molex Mini Fit Jr 39012205 Pinf Component Assignment WirColr na J1 6 1 7 J1 8 J1 9 J1 10 J1 11 Ji12 NotUsed 7 j Ji13 NotUsed 7 j Ter J1 15 Back Up Alarm optional 11 16 Throttle Output to Engine System 01 17 12 V for High Speed GRA BLU 18 1 J1 18 Neutral Relay K4 GRA WHT 18 1 J1 19 Horn Relay K1 VIO BRN 18 1 J1 20 BLK 18 2 Electrical System 59 Service Manual SW8000 Connector 2 2 Machine Controller Molex Mini Fit Jr 39012145 14 RETTER sistit Pin Component Assignment coor Electrical System 8 9 10 11 12 Glow Plug Indicator Light diesel only GRN RED 18 1 ight di Dust Control Filter Switch S5 optional WHT GRA 18 1 Hopper Interlock Switch S4 HED BLK 18 1 Ign Input PINK 18 1 Main Broom Switch S2 ORN BLK 18 1 2 1 12 14 BLK 18 3 Horn Relay K1 Bosch 3334485007 Pin Wire Color voss Lights Relay 2 Bosch 3334485007 Pin Wire coor SOS 7 voss VO164 60 Service Manual SW8000 Shaker Relay
157. nel enable the solenoid Valves corresponding to the selected functions The A2 Main Machine Controller will actuate the appropriate solenoid Valves to run the main broom side broom and dust control motors and extend the side broom cylinder when the following conditions are met The main broom is lowered and the Main Broom Switch S2 15 open The hopper is down and the Hopper Interlock Switch S4 1s closed The drive pedal is moved from neutral changing the resistance through the 5K Ohm Drive Pedal Sensor from its deadband range Service Manual SW8000 Hydraulic System 130 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 and Gear Pump are mounted on the rear of the engine toward the front of the machine and are driven by the engine crankshaft Hydraulic Manifold Assembly The Hydraulic Manifold Assembly is mounted on the frame underneath the center cover assembly DustGuard tank removed the adjacent photo Hydraulic 44 Manifold Assembly Service Manual SW8000 Hydraulic Oil Reservoir The Hydraulic Oil Reservoir is located below the Operator seat The hydraulic oil in the Hydraulic Oil Reservoir 1s at the correct level when it 1s halfway up the filter screen inside the reservoir fi
158. ng the sequence of code s 3 4 sec e 6 3 2 sec 1 4 sec pause pause J E m m Digit 2 Digit 3 Code Pin _ Comments e Check coil resistance If below 6 Ohms replace 8 Hopper close open solenoid L1 1 1 J1 1 ohms nominal Check wiring for a short circuit Blu Wht e Check coil resistance t If below 6 Ohms replace 8 1 2 J1 2 Main broom solenoid L2 overload ohms nominal Check wiring for a short circuit Grn Gra Service Manual SW8000 Control System 37 C Q e Check coil resistance t If below 6 Ohms replace 8 J1 3 Side broom solenoid L3 overload ohms nominal e Check wiring for a short circuit Brn BIk CO e Check coil resistance If below 6 Ohms replace 8 1 4 J1 4 Dust control solenoid L4 overload ohms nominal e Check wiring for a short circuit Brn Yel e Check coil resistance If below 6 Ohms replace 8 2 1 J1 5 Hopper up down solenoid L5 overload ohms nominal Check wiring for a short circuit Red Gra e Check coil resistance If below 6 Ohms replace 8 ohms nominal e Check wiring for a short circuit Blu Gra 22 Jt 6 Hopper up bypass solenoid L6 overload e Check coil resistance If below 6 Ohms replace 8 ohms nominal e Check wiring for a short circuit BIk Wht Hopper door open solenoid L7 2 3 J1 7 overload e Check coil resistance t If below 4 Ohms replace 6 oh
159. ns lt O 2 9 99 X189 X182 122 1 lt CONNECT TO X76 FOR CONNECT TO TERMINAL 1 ON 1 SP27 Ban LP14 M7 STROBE LIGHT OPTION VIO GRA 12 1 gt L 1 1 21502 R9 wf ka ON TOP OF CAB B M CAB OPTION Es M 5 H LAMP DOME 4 1 K8 C MOTOR DEFROSTER FAN 3 X63 uiis 26 85 d SWITCH FAN 2 gt E1 RED VIO 12 1 30 lt 9 8 X195 Ss CONNECT TO X83 ON SHEET 1 a RELAY HVAC CONTROL gt X179 OPTIONAL j CONNECT GENEL 162 VIO GRA 12 1 X183 WIRE AT X188 FROM K5 X194 BLK 18 20 CONNECT TO X204 ON SHEET 1 MT TOK ME zh YEL BLU X184 a lt 18 20 a Q CONNECT TO BLK WIRE AT X185 FROM K5 si X172 a 5 MI 1 1 YEL M6 fr CB9 2 2 RED M RED WITH A C SYSTEM Wo a 4 3 OHN X 1 6 IS NOT USED 2 170 PLUGS INTO X174 CIR BKR 20 AMP MOTOR BLOWER 3 X172 PLUSG INTO X175 HVAC 35 174 2 1 1 X175 y e d Sa cb E 1 BLK 18 31 az E lt lt 2 ni E 552 45159 2 SP28 22 66 8 Ja la zx 2259 Y oo ad amp a ae tc a ma azo 50 5 5 m o gt 2 1 E L10 x lt oO m ac E K10 al m X198 x199 H e ee 197 ANA AN AN AN 86 85 1 1 o ama 30 i
160. off the A C compressor motor This feature allows the machine to use the maximum available hydraulic force to raise the hopper 2 Note The Compressor Relay K10 coil control side is wired in parallel with the Hopper Up Negative Voltage The control side coil of the Condenser Fan Relay K9 must be connected to battery negative BLK wire The control side coil of the Compressor Hydraulic Valve L10 must be connected to battery negative BLK wire The control side coil of the HVAC Relay K8 must be connected to battery negative BLK wire Service Manual SW8000 Electrical Troubleshooting A gt Symptom both of the Blower Motors will not run One or both of the Blower Motors will not run Is there 12V at VIO GRA wire on Fan Switch S30 ref to bat neg w key switch on Reset or replace circuit breaker CB4 Is there continuity through 20A circuit breaker CB4 Yes Reset or replace circuit breaker CB9 Is there continuity through 20A circuit breaker CB9 No Yes Does the resistance of Relay coil K8 measure 850 420 Replace the No Relay Yes Is there continuity through the load contacts on 8 terminals 30 and 87 when the coil is energized Replace the No Relay Check the connectors and wiring and repair as necessary Options and Accessories 163 Note Refer to the Cab Electrical Wiring and Ladder
161. oid receives positive battery voltage and is grounded to the A2 Main Machine Controller when the Raise Hopper Switch is pressed Repair replace the wiring as necessary Check the solenoid coil resistance If the resistance doesn t measure approximately 9 ohms 10 replace the coil e Check the function of the solenoid valve cartridge Replace as necessary Check the function of the solenoid valve cartridge Replace as necessary Check for any mechanical binding or damage to the hopper pivot points hopper lift cylinder and cylinder mounting points Correct as necessary Service Manual SW8000 Hopper System 125 Problem 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 Hopper Switch is is not making connection panel and pin J3 8 on the A2 Main Machine Controller pressed with the A2 Main Machine If the connection is OK there may be a problem with Controller the touch pad switch panel or the A2 Main Machine Controller There is no power to the S9 Check the wiring to the S9 Hopper Lower solenoid Hopper Lower solenoid valve valve The solenoid receives positive battery voltage and is grounded to the A2 Main Machine Controller when the Lower Hopper Switch is pressed Repair replace the wiring as necessary The S9 Hopper Lower Check the solenoid coil resistance If the r
162. oil and filter cartridge after the first 50 hours of operation Change more often when operating under dusty conditions Tf you do not have the correct tools and or are not mechanically proficient contact your local KUBOTA dealer Engine Oil Check the engine oil level when the machine 1s parked on a level surface and the engine 1s cool Change the engine oil after the first 50 hours of operation and every 200 hours after that Engine oil should have properties of API classification SL or higher and be suited to the ambient temperature as listed below 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 SAE30 SAE10W 30 or SAE15W 40 32 F to 77 F 0 C to 25 C SAE20 or SAE 10W 30 4 F to 32 F 20 C to 0 SAE10 or SAE 10W 30 Engine Coolant Checking Engine Coolant Ay Caution Do not remove the radiator cap when the engine is hot To check the engine coolant level open the engine cover and observe the coolant level in the coolant overflow tank If the level 1s low add a 50 50 mix of water and the recommended type antifreeze Clean the radiator and oil cooler exteriors every 150 hours by washing with low pressure water or using compressed air High pressure water will damage the radiator A Service Note The oil cooler tips out for easy cleaning of both the oil co
163. oil resistance is within spec disassemble the Hydraulic Valve and clean or replace the cartridge as necessary Hydraulic 4 k Wie Hydraulic Valve L10 4 Pressure Accessory Electrical Hydraulic Connector Pump Figure 8 Compressor Motor Hydraulic Valve Service Manual SW8000 Options and Accessories 166 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 The following chart shows pressure values that are representative of what you should be reading at normal operating temperature if the Accessory Hydraulic Pump Hydraulic Valve and compressor motor are working correctly Note that pressures tend to be higher if the hydraulic system is below normal operating temperature ifference in Hydraulic EE at Test Pressure between A C off Engine at idle A C off 500 psi 380 psi Engine at idle A C on 880 psi Engine at high speed A C off 675 psi 425 psi Engine at high speed A C on 1100 psi If you don t observe differences in the hydraulic pressures similar to those in the above chart when switching the A C on and off 1t could indicate a problem with the Hydraulic Valve L10 the Accessory Hydraulic Pump
164. oler and the radiator Service Manual SW8000 Replacing Engine Coolant Engine System Gasoline LPG 105 One possible cause of engine overheating 1s 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 typical type of tool Refer to the operating instructions included with your particular tool if different than the example shown here L Connect a Compressed Air Supply Line to the fitting on the Cooling System Tool Connect the Coolant Supply Line to the Cooling System Tool Make sure the Coolant Valve is closed Insert and hold the Cooling System Tool onto the radiator filler neck then press the Air Switch The compressed air travelling through the Venturi Tube Assembly will pull a vacuum on the cooling system to remove air from the system Once the vacuum reading on the Gauge reaches approximately 25 on the green scale release the Air Switch Note that this also a good opportunity to check for cooling system leaks Continue to hold the Cooling System Tool onto the radiator filler neck and open the Coolant Valve to allow coolant to flow into the radiator Once the pressure on the Gauge reaches approximately 5
165. om the drive position sensor 5 The Fault Code Light S will indicate the dead band setting as described below To change the dead band sensitivity press the Engine Speed switch to cycle through the 9 options Narrow Steady on Medium Slow flash Default Wide Rapid flash 6 Tosavethe settings and exit the process turn off the keyswitch Recall of Stored Fault Codes Past fault codes are stored in memory and may be retrieved and cleared as part of maintenance history 1 Make sure the keyswitch is in the off position 2 While holding the Horn switch D turn the keyswitch A to the on position Continue to hold the Horn switch until all display indicators turn off approximately 2 seconds 3 When the Horn switch 1s released the Fault Code Light S will flash out the error codes If no past error codes exist the light will remain steady on 4 clear the fault code history press and release the Horn switch The Fault Code Light will change to steady on 5 To exit turn the keyswitch off Service Manual SW8000 Control System 36 Automatic Shaker Operation This adjustment enables or disables the automatic shaker option and how the shaker functions when 1t 1s active 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
166. ooms A left hand side broom 1 available as an option Service Manual Purpose and Application This Service Manual 1 a technical resource designed to aid service personnel in maintaining and repairing the SW8000 Sweeper to ensure optimum performance and long service life Please read it thoroughly before servicing your machine Other Reference Manuals and Information Sources Nilfisk Advance Publications Model Name Model Number Instructions for Parts List Form Use Form Number Number Advance SW8000 4 Cylinder LPG 56107503 56042600 Advance SW8000 4 Cylinder Gasoline Petrol 56107501 56042602 Advance SW8000 4 Cylinder Diesel 56107505 2 Advance SW8000 4 Cylinder LPG Cab 56107509 A Portuguese 56042601 Advance SW8000 4 Cylinder Gasoline Petrol Cab 56107507 Advance SW8000 4 Cylinder Diesel Cab 56107511 These manuals can be found in the following locations EzParts within Nilfisk Advance Dealer Customer Zone website or EzParts CD ROM Nilfisk Advance website www Nilfisk Advance us com Engine Manufacturers Technical Manuals Engine Type Publication Title Kubota 05 Series Service Data Book 9Y110 00051 pdf Workshop Manual Diesel Engine 05 Series WG1605 9Y111 00126 pdf 0 Woodward Product Specification 03399 APECS 0175 Series Actuators Specifications WG1605 9Y110 01770pdf workshop Manual 18059 11106610 biagnosis Manual EOM System WG16059YHO 0760gdf
167. operated cartridge valve Dust Control Bypass Solenoid actuated 3 2 directional spool direct acting cartridge valve Used on S1 S7 S9 12 VDC nominal coil resistance 9 Q Used on S8 12 VDC nominal coil resistance 6 5 eA Note The following solenoid valves are interchangeable gt 51 2 S3 and S7 55 and 59 Also note that 51 52 53 55 56 57 59 all use the same solenoid coil Service Manual SW8000 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 Hydraulic System 139 Service Manual SW8000 Hydraulic System 140 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 Side Broom Lift Cyl 1 00 x 1 18 x 50 es vv mE Side Broom Speed Control Option Hopper Dump Cyl Broom Steering Cyl 1 5 x 3 75 x 79 Motor 1 75x8 5x 75 Piloted D Check Valve 4 O x C MM Loud Side TES Dust Control l Bypass Steering NE 4 88 CIR ME 6 j Captive Plug ton aus Hopper EE Lower Up Bypass as LE y 5 Dust Filter 2500 e
168. opper opan i Broom 2 0 eue 2 T wa 9 m b 6 i Hopper Up Bypass s 1 _ t From Dust 5 Control 2500 CZ PSI Hopper To Oil Cooler Up Down and Filter T P 1 Gear Pump RPM CIR EN wn MEN 2 2 2 Q2 21 Lr Reservoir When the hopper is down and the main broom is off the hydraulic oil from the Gear Pump passes through the 8 6 GPM splitter through the de energized Hopper Up Bypass solenoid valve S6 then through the return lines to the Oil Cooler and Filter When the hopper door is closed the hydraulic oil from the Gear Pump passes through the de energized Hopper Open solenoid valve S7 then to the retract lower port B on the extended Hopper Dump Cylinder The check valve on the de energized Hopper Close Open solenoid valve S1 blocks the oil flow through the Hopper Dump Cylinder to keep the Hopper Dump Cylinder extended and the hopper door closed Service Manual SW8000 Hopper System 117 Raise Hopper To From Steering Steering Main 2 Broom Up Bypass End i ug _ From Dust S5 Control Hopper LZ3 Up Down 71 To Cooler 4 and Filter T P LE Hopper Lift Cylinder Raises Hopper i Gear Pump 2400 i RPM 1 02 Reservoir When the Raise Hopper Switch on the control panel is
169. out Overhead Guard Service Manual SW8000 Description Illustration Work Light Kit The Work Light Kit includes three lights S a Curb Work Light a Rear Work Light and a Trouble Light Back Up Alarm Kit The Back Up Alarm Kit includes the Back Up Alarm electrical connector and mounting hardware The Back Up Alarm connects to the existing machine wiring to sound a warning when the machine is moving in reverse Brake Signal Light Kit Options and Accessories 147 Service Manual SW8000 Options and Accessories 148 Description Illustration Overhead Guard Kit Amber Strobe Kit without Overhead Guard Service Manual SW8000 Options and Accessories 149 Description Illustration Amber Strobe Kit with Overhead Guard Cab Side Mirror Option Raised Air Intake Kit for use with Cab Service Manual SW8000 Options and Accessories 150 Description Illustration Amber Strobe Kit for use with Cab Service Manual SW8000 Options and Accessories 5 8000 Deluxe Cab Options The SW8000 Deluxe Cab is available w ith two levels of environmental control that provide additional comfort and convenience for the Operator and add additional functionality to the machine 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 1s available that provides Operator
170. pecial Tools Cooling System Tool Diesel Compression Gauge There are many brands of compression gauges available Shown is a Snap On EEPD500 Gauge kit Compression Gauge Fitting for Glow Plug threads Shown is the Snap On TU 15 35 Threads M8 X 1 0 Service Manual SW8000 Engine System Diesel 94 Gauge Coupler If using the Snap On diesel compression EEPD500 Gauge kit and Snap On TU 15 35 glow plug thread fitting a coupler must be used to join the fitting to the gauge hose Shown are Snap On couplers M3569 and M3570 Nilfisk Advance Service Manual SW8000 95 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 2 Note Also refer to the following manufacturer s technical literature Operators Manual 1605 EG523 89162ENG pdf Engine Specifications 1605 9Y110 01770 pdf Workshop Manual 1605 9Y111 06610 pdf Diagnosis Manual ECM System WG1605 9Y110 01760 pdf Engine Description The Kubota WG1605 G E3 gasoline and WG1605 L E3 LPG are four cylinder liquid cooled naturally aspirated engines Kubota 1 6L Gasoline Fuel System Description This engine uses an electric fuel pump to pump gasoli
171. pper Safety Support Handle operates the Hopper Safety Support To engage the Safety Support 1 To disengage the Safety Support 1 3 Raise the hopper to its full up position Pull the Hopper Safety Support Handle toward the rear of the machine to engage the Safety Support as shown here Lower the hopper to rest on the Safety Support Raise the hopper to its full up position Push the Hopper Safety Support Handle toward the front of the machine to the to the disengaged position Hopper Safety Support Operation Lower the hopper Jacking The Machine Caution Never work under a machine without safety stands or blocks to support the machine When jacking the machine do so at designated locations Do Not jack on the hopper Jack Location On Weight Service Manual SW8000 General Information 14 Transporting The Machine Caution Before transporting the machine open truck or trailer make sure that All access doors are latched securely he machine parking brake is set The machine is tied down securely see tie down locations in following figures Tie Down Right Front Tie Down Right Rear Service Manual SW8000 General Information 15 Towing Or Pushing A Disabled Machine The machine s drive propelling pump is manufactured with an adjustable tow valve This valve prevents damage to the hydraulic system wh
172. pper door pivot points hopper door cylinder and cylinder cylinder mounting points Correct as necessary Service Manual SW8000 Hopper System 126 Problem Correction The hopper door The Close Dump Door Switch Check the connection between the touch pad switch doesnt close when is not making connection panel and pin J3 7 on the A2 Main Machine Controller the Close Dump Door with the A2 Main Machine If the connection is OK there may be a problem with Switch is pressed Controller the touch pad switch panel or the A2 Main Machine Controller There is no power to the 1 Check the wiring to the S1 Hopper Close Open Hopper Close Open solenoid solenoid valve The solenoid receives positive battery valve voltage and is grounded to the A2 Main Machine Controller when the Lower Hopper Switch is pressed Repair replace the wiring as necessary The S1 Hopper Close Check the solenoid coil resistance If the resistance Open solenoid valve is not doesn t measure approximately 9 ohms 10 operating replace the coil e Check the function of the solenoid valve cartridge Replace as necessary The S7 Hopper Open solenoid Check the function of the solenoid valve cartridge valve is stuck in the energized Replace as necessary position There 1 dirt or debris Clean remove any dirt or debris from the hopper preventing the hopper door door and door sealing surfaces from closing There is binding in the hopper Check
173. precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts Before use all doors and hoods should be properly latched The battery must be removed from the machine before the machine is scrapped The disposal of the battery should be safely done in accordance with your local environmental regulations Do not use on surfaces having a gradient exceeding that marked on the machine All doors and covers are to be positioned as indicated the instruction manual before using the machine Hopper Safety Support Warning Make sure the Hopper Safety Support is place by using the Hopper Safety Support Handle whenever attempting to do any maintenance work under or near the raised hopper The Hopper Safety Support mechanically holds the hopper in the raised position to allow work to be performed under the hopper NEVER rely on the machine s hydraulic components to safely support the hopper See To Engage The Safety Support below Hopper Safety Support 1 M m IPS 777 JP si RAM LL Nw Hopper Safety Support Service Manual SW8000 General Information 13 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 the hydraulic system The Ho
174. pressed the A2 Machine Controller energizes the Hopper Up Down solenoid valve S5 and the Hopper Up Bypass solenoid valve S6 The check valve 1 the energized Hopper Up Bypass solenoid valve blocks and directs the hydraulic oil to the energized Hopper Up Down solenoid valve S5 The hydraulic oil also deadheads at the check valve the de energized Main Broom solenoid valve S2 at the de energized Hopper Lower solenoid valve S9 and at the Captive Plug in the pressure line The hydraulic oil goes through the energized Hopper Up Down solenoid valve S5 then to the extend lower port N on the Hopper Lift Cylinder to raise the hopper The oil from the retract upper port M on the Hopper Lift Cylinder goes to the return line to the Oil Cooler and Filter Service Manual SW8000 Hopper System 118 Lower Hopper To From Steering Steering Main i S2 Broom Hopper Up Captive Plug 71911 From Dust Control Hopper To Oil Cooler Up Down and Filter T Hopper Lift Cylinder Lowers Hopper 2400 i RPM 1 02 CIR Reservoir I 1 i L 6 m L 1 L When the Lower Hopper Switch on the control panel is pressed the A2 Machine Controller energizes the Hopper Lower so
175. r 2400 RPM Steering System 177 Steering Cylinder Moves Drive Wheel to Steer Machine Toward the Left Rotary 4 Valve Rotary Meter O LIS T P VT PI 2 1 Hydraulic Manifold Pump Assembly Woe CIR 1 Reservoir Service Manual SW8000 Steering Wheel Held in Full Right or Left Position When the steering wheel 1s held to the stop in its full right or full left turn position full left 15 shown here the Relief Valve opens up to allow the hydraulic oil to pass through the Relief Valve and to the Oil Cooler and Filter The Relief Valve will also open if something 1 preventing the drive wheel from rotating to steer To Oil Cooler and Filter 2400 RPM Steering System 178 Steering Cylinder Stationary with Steering Wheel Held at Full Stop SS L R Rotary Valve wer fk 1100 24 4 Relief Tu eT Valve ERN i Hydraulic Manifold Assembly 1 02 GIR Reservoir Service Manual SW8000 Steering System 179 Turning the Steering Wheel with the Engine Off When the engine is off and no hydraulic oil is being Steering Cylinder pumped to the Rotary Valve and Rotary Meter the 2 Rotary Meter acts like pump when the steering wheel Toward the Left is turned The Check Valve opens to allow the oil pumped from the Rotary Meter to flow to and from the Steering Cylinder to allow the m
176. rance Minimum ceiling height dumping clearance Weights Gross weight without cab Gross weight with cab Sweep System Main broom length Main broom diameter Main broom bristle length oweeping path w single side broom Sweeping path w dual side brooms Side broom diameter STD Side broom bristle length Height w Overhead Guard General Information 16 English Metric NY AS Et Front View Width Front View 95 inches 2241 cm 64 163cm 59 inches 150cm 81 25 inches 206cm 79 inches 201cm 3 5 inches 8 9cm 101 4 inches 257 5cm 4426 Ibs 2007kg 4775 Ibs 2165kg 50 inches 127cm 14 inches 35 5cm 3 25 inches 8 26cm 65 inches 165cm 77 inches 196cm 26 inches 66cm 6 inches 15 2cm Width minimum Width of machine body at the hopper no side brooms Gross Weight Standard machine without options with 175 Ibs operator with standard sweeping brooms and full tank of fuel Service Manual SW8000 Technical Specifications Hopper System Capacity Lifting capacity Dump height variable Dump height with door open Dust Control System Filter type Pleated paper panel STD optional poly filter available Filter media area Filter dimension Dust Guard Water Misting Tank Capacity Steering System Type Full power steering unit and hydraulic cylinder Turn radius left Turn radius right Minimum aisle turn width left Hydraulic System Oil type SAE 10W
177. rent pedal position If it senses that the drive pedal is NOT in the neutral position it energizes the neutral relay to break the connection between 30 and 87a This prevents the starter from engaging Crank B SW Crank and Run Neutral Relay K4 Starter Solenoid Drive Pedal Sensor Input Neutral Main Machine Controller Service Manual SW8000 Engine System Gasoline LPG 97 Crank and Run 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 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 115 deg C it will shut down the engine Engine Speed Control The operator can request two engine speeds idle and full throttle The Engine Controller operates an Electronic Throttle Body to adjust and maintain engine speed according to the requested input of the Main Machine Controller To request full throttle the main machine controller sends out a 12v supply from J1 17 on the GRA BLU wire to the engine controller To request idle the main machine controller does not apply 12v the
178. replace wire to controller and check the voltage at the plug Batt to Gra Orn 12V Repair replace wire to pump Bat to Blu 12V Confirm 12 volts Repair replace wire to breaker at CB8 breaker Bat to Blu Orn 12V Confirm 12 volts Repair replace wire to switch at S26 switch Service Manual SW8000 Dust Control System 49 Specifications Parameter Misting pump relay coil resistance Shaker motor relay coil resistance Dust control misting valve coi resistance Dust control vacuum valve coi resistance Nilfisk s Advance Service Manual SW8000 50 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 The gauge panel assembly panel includes the Fuel Level Gauge gas and diesel machines only Hour Meter Panel Assembly A2 Main Machine Controller and the Starter Switch The Panel Assembly contains the touch pad membrane switches and indicators that allow the Operator to enable and disable the sweeping functions raise and lower the hopper open and close the hopper door control the engine speed sound the horn and switch the headlights on and off The A2 Main Machine Controller is a compu
179. resistance values are not close to those shown the above table it indicates that the feedback potentiometer in the Valve Assembly is not working correctly Replace the Valve Assembly Service Manual SW8000 To Troubleshoot the Heater Temperature Control There is no Cab heat the Cab heat cannot be controlled Is there 12V to the Heater Temperature Control BLK and RED wires Is there approximately 9 75 V at the Valve Assembly Connector BLK WHT and ORN wires when the Heater Temperature Control E1 is rotated between cold and hot Is there continuity in the three feedback pot wires WHT VIO and GRN from the Heater Temperature Control to the Valve Assembly Connector Replace the Heater Temperature Control Check the wiring to the Heater Temperature Control and repair as necessary Is there continuity in all five wires from the Heater Temperature Control to the Valve Assembly Connector Replace the Heater Temperature Control Repair the wiring as necessary Options and Accessories Repair the wiring as necessary BA Service Note If you have to replace the Heater Temperature Control in the cab we recommend that gt you do so as follows 1 Remove the Overhead Control Plate from the cab 2 Disassemble the Heater Temperature Control from the Overhead Control Plate 3 Cut the seven wires going to the Heater Temperature Control at the point where th
180. running nothing else running Measured Motor Speed 103 RPM 130 RPM 405 RPM 8 920 RPM Machine Condition Service Manual SW8000 Hydraulic System 136 Checking the Piston Pump Pressure MA Note Checking the piston pump hydraulic pressure will require you to assemble the appropriate et fittings that will allow you to connect your pressure gauge to a suitable location Measured Pressure from the Piston Pump Machine Condition Level surface 70 F ambient temperature Pedal fully depressed 700 psi empty hopper and tank Pedal 1 2 depressed 600 psi Hydraulic Truth Table ee Solenoid Function Hopper Rass UP L 1 LE x x LL Hopper Lower DN J o S j Dump Door Open J X J J S j _ Dump Door Closed emm o dxlxl o Rc pote Main Side Broom State ON X Dust Control ON Wand State Dust Control OFF Bypass Side Broom Lower Side Broom Lower Lower Side Broom Raise amp Turn oV Side Broom Motor No Hydraulic Manifold i overload energized Functions in relief Operator sweeping wet debris with the dust control fan impeller turned off Operator using vacuum wand option The dust control fan operates when the machine s drive is stationary To vacuum attach the suction hose wand to the special hopper inlet fitting The S6 solenoid valve assembly bypasses the sweep system components and sen
181. shooting oaa 194 Side Broom Won t 194 Side Broom Won t Raise 195 SIUE Broom WOR TIOWE REE ERA _ XS 40 195 SPECICATION S e 2 1 3 9x3 9345 4905 6 93x 195 Wheel System Non Traction 196 Functional Description ooo 196 Maintenance and 196 Troubleshooting S E WR ROS 196 Removal and lt 196 Remove and Reinstall d Wheel xw wem x xo Roche 3 9 ox eee deduced 196 To Remove and Reinstall a Brake and Spindle 197 Wheel System 198 lt 198 ca eee epee eee eee eee Eee 44 2 4 E 198 Piston drive Pump and Drive 198 Foot Pedal Assembly 199 Forward Reverse 199 200 Electrical Schematic and Circuit lt 200 Hydraulic
182. sult in serious Warning Bleeding the system can result in diesel fuel being spilled the machine and personal injury or death Do not bleed the fuel system on a hot engine as fuel spilled onto a hot exhaust manifold can catch fire Bleed the fuel system in a well ventilated area and observe all applicable safety precautions Always wear the recommended personal protective equipment PPE including eye protection 1 Make sure the fuel tank 1s not empty 2 Connect switched jumper wires from the battery to the electric fuel pump so you can run the fuel pump with the ignition switch off before you bleed the system This will minimize the amount of air remaining in the 2 Service Note If you ve removed or replaced the fuel filter element fill the filter canister with fuel M filter 3 Turnon the fuel pump Service Manual SW8000 Engine System Diesel 86 4 Slightly loosen the Bleed Screw on top of the Fuel Filter to remove the air from the fuel line and Fuel Filter 5 When no more bubbles can be seen at the Fuel Filter Bleed Screw and the fuel is running clear tighten the Bleed Screw 6 Repeat steps 4 and 5 above as needed to remove all of the air from the fuel line and Fuel Filter Note that you may need to do this four or five times 7 Use a wrench to hold the Injector Pump base stationary then slightly loosen the Bleed Screw on top of the Injector Pump to remove the air from th
183. symbols below are used to help you recognize this information Warning Indicates a potentially hazardous situation which if not avoided could result in death or Serious Injury Caution Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury Caution When used without the Safety Alert Symbol indicates a potential situation which if not avoided could result in property or machine damage Service Manual SW8000 General Information 11 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 This machine is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge While on ramps or inclines avoid sudden stops Avoid abrupt sharp turns Use low speed down ramps To avoid hydraulic oil injection or injury always wear appropriate clothing and eye protection when working with or near hydraulic system Turn the key switch off O and disconnect the batteries before servicing electrical components Never work under a machine without safety blocks or stands to support the
184. t code light U on the display panel The error code s are used to help the service person determine the fault and to quickly guide in repairing a specific system malfunction An additional special feature of the main control board is to change program settings for a set of specific machine functions See the section Main Machine Controller Programming described on page 35 for further information Service Manual SW8000 Control System 34 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 Main Machine Controller Optional DustGuard and Signalling Switches Hydrostatic Drive Position Sensor Engine Controller _ i g r zz m i i re NW L L bs T Ij Service Manual SW8000 Control System 35 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
185. t the main broom is running The main broom must be active with the throttle position Troubleshoot the sensor out of neutral before main broom function the vacuum motor will run Disconnect the electrical Remove the S8 solenoid connector from the 58 valve and examine it for solenoid Does the a stuck plunger Replace vacuum motor run the valve if necessary No Replace the vacuum motor Done Inspect the brown wire from the S8 solenoid to the J1 8 Repair replace connector on the control the wiring board for a short to ground Is the dust control LED illuminated on the control panel display Replace the main control board Turn the machine off Press and hold the dust control switch and Yes check for continuity between the J3 1 and J3 10 pins on the ribbon cable connector Replace the main control board Replace the display panel Done 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 f Note In the decision tree below all function prerequisites are assumed to be true for th
186. tay lowered when Yes Piloted valve V1 is stuck main broom is off Replace the valve Done No Check for 12 V at side No Side broom solenoid 3 broom solenoid S3 stuck Replace solenoid Bens Yes Confirm the function of the side Replace the controller Is 12V still present even No broom membrane aulicus when main broom is off Between J3 1 and J3 9 12V not pressed Replace the Yes OV continuity when pressed Display Done Done With machine off disconnect cable from controller and Yes Repair replace D solenoid and check for short to cable is ground No Replace the Side Broom Won t Lower If the side broom rotates but will not lower that is an indication that high pressure hydraulic fluid is present at both ports of the lift cylinder at the same time The pilot controlled valve V1 1s stuck If the side broom neither rotates nor lowers then use the Side Broom Won t Run troubleshooting procedure described on page 194 Specifications Parameter Nominal Resistance Side Broom Solenoid resistance Nilfisk f Advance Service Manual SW8000 196 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 the wheel wells on the front sides of the machine between the main
187. ter A Port on Drive Motor Supply from Reservoir Hydraulic Manifold Assembly 296 ij Digs d Door Cylind To Hopper Lift Cylinder Return to Reservoir To Side Broom Motor and Lift Cylinder From Gear Pump Heturn to Filter Cooler and Heservoir To Hopper Door Cylinder To Steering Control Unit er Service Manual SW8000 Electrical Schematic 2 L CB1 Circuit Breaker 70 Amp CB4 Circuit Breaker 20 Amp GRN BLU 1 2 Electrical Circuit Description e a VIO Hopper Close Open Hopper Up Down Hopper Up Bypass Dust Control Bypass Battery 12 VDC 1 1 A2 Machine Controller o Bat o Bat o Bat 0 Bat o Bat o Bat 0 Bat o Bat 5v 5v 5v 5v 5v 5v 5v 5v Hydraulic System 129 BRNWHT J 2 2 ORN GRA 2 12 3 E 1 2 3 Drive Pedal Sensor Ohm 12 12 ORN BLK 1 2 2 BLK Main Broom Switch Open when Broom is Down 2 9 RED BLK 1 54 2 Hopper Interlock Switch Closed when Hopper is Down Touch Pad Switches 3 10 J 3 1 2 Dust Control 3 9 13 12 2 Side Brooms 3 5 n ve l L2 Hopper Door Open 3 6 1 4 2 3 8 13 1 4 2 Hopper Down TPS10 13 11 2 Hopper Door Close 3 1 4 Common Ground The Touch Pad Switches on the control pa
188. ter between the two wires at the device or between J1 11 and the listed J from the table The ohmmeter should show open circuit od 1 14 3 3 3 4 i When testing a coil resistance disconnect the connector at the device and use ohmmeter to measure the resistance of the coil If the value is below the minimum value from the table replace the device Service Manual SW8000 Control System 38 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 1 Turn offthe key switch and disconnect the battery cable connector 2 Remove the 3 screws 2 that secure the operator interface to the dash 3 Lift the operator interface away from the dash taking care not to stress the wiring harness 4 Disconnect J1 J2 J3 and J4 from the control board A2 5 Remove the two screws 3 that secure the control board and remove the ground wire 4 6 Remove the control board 7 After replacing the control board with a new one set the Hydrostatic Neutral Position and Dead band described on page 35 8 If necessary also set the Automatic Shaker Operation described on page 36 Service Manual
189. terized controller that receives inputs from the membrane switches and the system components and provides output voltage to the various solenoid valves relays Panel Assembly indicators etc Panel Fuel Level Assembly Gauge Gas and A2 Diesel only Control Box Assembly Service Manual SW8000 Circuit Breaker Panel Assembly The Circuit Breaker Panel assembly 1s mounted below the instrument panel hopper switches and includes the Circuit Breakers and the SPDT Relays Note that diesel models have an additional SPDT Relay Models equipped with the DustGuard system have an additional 10 amp Circuit Breaker and SPDT Relay for the misting pump Models equipped with the optional signal lights will have an additional 20 amp Circuit Breaker and SPDT Relay Models equipped with the cab HVAC option will have an additional 20 amp Circuit Breaker and two additional SPDT Relays Electrical System Circuit Breakers 51 Service Manual SW8000 Electrical System 52 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 2 on Circuit Breaker CB6 n the bottom right photo one side of the gray blue wire goes to pin J1 17 the A2 Main Machine Controller The other side of the wire goes to terminal K on connector X2
190. th every oil change Temperature Range Oil Weight Above 77 F 25 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 SAE 10W or 10W 30 Diesel Lubricating Oil Note With the emission control now in effect the CF 4 and CG 4 lubricating oils have been developed for use with a low sulfur fuel used in on road vehicle engines When an off road vehicle engine runs on a high sulfur fuel it is advisable to employ the CF CD or CE lubricating oil with a high total base number If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter intervals Lubricating pus High sulfur Remarks Oil class 7 Refer to Kubota Diesel Engine Workshop Manual O Recommended X Not Recommended Engine Coolant Checking Engine Coolant Caution Do not remove the radiator cap when the engine is hot To check the engine coolant level open the engine cover and observe the coolant level in the coolant overflow tank If the level is low add a 50 50 mix of water and the recommended type antifreeze Clean the radiator and oil cooler exteriors every 150 hours by washing with low pressure water or using compressed air High pressure water will damage the radiator Service Manual SW8000 Replacing Engine Coolant Engine System Diesel 83 One possible cause of engine overheating 1s trapped air in the cooling system It s recommended that you use
191. tinuity across the two terminals M Note The Thermostat is normally closed and should have continuity across the terminals at oi ambient temperatures above 31 F is continuity across the terminals the Thermostat is working correctly is very high resistance or no continuity across the terminals replace the Thermostat cooler or canned air dusting spray onto the probe embedded in the evaporator coils 2 Service Note To verify that the thermostat is operating correctly spray electronic component nh to cool the probe to below 31 The Thermostat should open and you should read an open circuit through the terminals with the probe below 31 F Once the probe warms up to 39 5 there should again be continuity through the Thermostat terminals Service Manual SW8000 Options and Accessories 170 Thermostat 533 Figure 11 Checking Continuity through the Thermostat Service Manual SW8000 Options and Accessories 171 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 10 High Pressure Liquid L410 energized 12V AC turned ON Nilfisk Advance Service Manual SW8000 Steering System Functional Description Overview The steering system inc
192. tions 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 Cam Sensor and Crank Sensor Oscilloscope Pattern 3000 Kubota 1 6 ms SVVa000 Kubota 1 8 Service Manual SW8000 Engine System Gasoline LPG Special Tools Diagnostic Communication Cable and software p n 56305647 CD is for the GM engines New software and a new password must be downloaded from Customer Zone to use on the Kubota engine Note The cable is used but the software on the Cooling System Tool Nilfisk s Advance 110 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 hopper filter to reduce the dust generated from sweeping Refer to the Dust Control System section for more information on the dust control components Hopper The Hopper is supported by the Hopper Lift Arm Weldment The Hopper Lift Arm Weldment pivots
193. uring tolerances and system oil temperature If any reading varies greater than 20 percent there will be a noticeable loss of performance and the problem should be corrected Service Manual SW8000 Hydraulic System 135 Checking the Gear Pump Pressure MA Note There is Test Port on the Gear et Pump that can be used to check the Gear Pump pressure 1 Connect the pressure gauge to the Test Port on the Gear Pump 2 Runthe engine in the high throttle position and allow the hydraulic oil to warm up 3 Refer to the following tables to determine if the gear pump and or hydraulic motor 1 operating correctly static taken on a smooth painted concrete surface Note of the following readings were f the f g g Measured Pressure at Machine Condition the Gear Pump Test Port High RPM nothing running 380 psi High RPM main broom only running standard broom two inch wide brush pattern on 1 275 psi concrete vacuum fan turned off High RPM main broom off vacuum fan turned on side brooms off 1 650 psi High RPM main broom on two inch wide brush pattern on concrete vacuum fan 1 770 psi turned on side brooms off High RPM main broom on two inch wide brush pattern on concrete vacuum fan 1 810 psi turned on side brooms on High RPM raising empty hopper Time to raise hopper 10 11 seconds dius High lowering empty hopper Time to lower hopper 7 seconds One side broom
194. use for tracking maintenance tasks Fuel Gauge For gasoline or diesel engines only Shows the level of the fuel in the fuel tank Horn Switch D Activates the horn Propane Low Indicator E The lamp illuminates when the propane tank 1 empty Headlight Switch F Turns the headlamps on and off Check Engine Light G The lamp illuminates when the engine controller signals a problem exists with the engine Glow Plug Indicator H diesel engine only The lamp is illuminated while the glow plugs are active Diesel engine glow plugs preheat the cold cylinders before starting then engine The glow plugs are activated when the ignition switch is turned to the counterclockwise position Engine Speed Switch I Switches between idle and run speed rpm of the engine Do not drive or otherwise operate the machine while the engine is at idle Side Broom Down Up Switch J Raises and lowers the side brooms Dust Control Switch K Turns the dust control fan on and off Dust Control Indicator Illuminates when the dust control fan 1s active Shaker Switch L Turns the shaker on and off The dust control fan automatically turns off while the shaker 1s active The shaker 1s used to clean debris from the filter Plugged Filter Indicator Optional equipment The LED on the shaker switch illuminates when the pressure sensor indicates the filter 1s clogged Service Manual SW8000 Control System 32 Hopper Up Indicator
195. vice Manual SW8000 General Information 27 Engine Compartment Cover 4 Hopper Cover Prop Rod Tie Down Locations 5 mu m H rj 7 PAAL H m a 7 H 7777 FM Right Side Main Broom Access Panel Fuel Tank Cover Release Latch Oil Reservoir Fuel Tank Cover j v 1 iL 27 OS ja E j Iw E 59 1f _ E Oil Reservoir i a Fuel Tank LPG tank shown Gasoline Petrol tank is in same location Know Your Machine Service Manual SW8000 General Information 28 Operator s Compartment Main Broom Adjust Knob Steering Wheel Control Panel Operator s Hopper Safety Brake Pedal FWD REV Seat Support Handle Parking Brake Drive Pedal Operator Seat Adjustment Lever under seat Circuit Breaker Panel Know Your Machine Service Manual SW8000 General Information 29 Control Panel Horn Switch Fuel Gauge Not LPG Propane Low Indicator Check Engine Indicator Glowplug Indicator Diesel Only VERBI Headlight Switch Engine Speed Switch Side Broom Switch Dust Control Vacuum Switch Shaker Switch Raise Hopper Switch Open Dump Door Switch Hopper Up Indicator Hopper Over Temp Indicator Close Dump Door Switch Key Switch Check Engine Hour Meter Indicator Lower Hopper Switch Optional DustGuard and Signallin
196. vice Manual SW8000 Sweep System Side Broom 194 Troubleshooting Side Broom Won t Run Side Broom will not run when the switch is on No The side broom cannot operate Verify that the main unless the main broom is running broom is turning Troubleshoot the main broom Yes Is the side broom Yes firmly locked in the Replace the side broom motor Done down position No Is one side broom working Yes Piloted check valve C1 stuck Bons but second side broom not in open position Replace No Replace the Don solenoid SS Check for 12 volts at the Yes side broom solenoid S3 NO If equipped does the Yes Control board working properly d i Repair wiring between control Done misting pump function SEEN board and solenoid No or not equipped Check for 12 volts between J1 11 and J1 3 at the control board Confirm the function of the side Replace the broom membrane switch controller Between J3 1 and J3 9 12V not pressed OV continuity when pressed coi Done Done Service Manual SW8000 Sweep System Side Broom 195 Side Broom Won t Raise If the side broom stops rotating but won t raise that 1s 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 S
197. zard that can result in serious personal injury or death Warning Replacing the fuel filter can result in diesel fuel being spilled on the machine and Do not replace the fuel filter on a hot engine as fuel spilled onto a hot exhaust manifold can catch fire Replace the fuel filter in a well ventilated area and observe all applicable safety precautions Always wear the recommended personal protective equipment PPE including eye protection 1 Place a pan or other suitable receptacle underneath the fuel filter to catch any spilled fuel Service Manual SW8000 Engine System Diesel 85 2 Unscrew the Fuel Filter from the Fuel Filter Housing 3 Pre fill the new Fuel Filter with clean diesel fuel to minimize the amount of air that will v need to be bled out of the fuel system Fuel Filter Housing T 4 Screw the new Fuel Filter onto the Fuel Filter Housing k 5 Bleed the remaining air out of the Fuel Filter Refer to the Bleeding the Fuel System subsection below Bleeding the Fuel System The electric fuel pump on the fuel tank pumps fuel to the fuel filter The fuel flows through the filter to the injector pump on the engine The injector pump pumps fuel under high pressure to the injectors Youll need to bleed the fuel system whenever the fuel filter element is removed replaced or if the machine runs out of fuel surrounding areas This can present a potential fire hazard that can re

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