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SERVICE MANUAL

ENGLISH

RS 501

33015500(3)2008-02

73

LDW 1603/B2 ENGINE

LDW 1603/B2 ENGINE

DESCRIPTION

The machine is equipped with a diesel engine, which activates the hydraulic system pumps.
For diesel engine data see the Technical Data chapter and the Diesel Engine Manual.

The following pumps are connected to the engine:

Accessory and steering system pump
Suction fan pump
Drive system pump

The fuel fi lter is located on the machine frame.
For machines equipped with climate control system, besides the alternator control pulley, there is also the compressor control pulley
(D).

A

B

C

D

S301413

A)
B)
C)

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Summary of Contents for RS 501

Page 1: ...RS 501 ENGLISH SERVICE MANUAL 33015499 3 2008 02 ...

Page 2: ......

Page 3: ...INLET DISASSEMBLY ASSEMBLY 33 SKIRT REPLACEMENT 34 HOPPER POSITION ADJUSTMENT 35 HOPPER LID CLOSING ACTUATOR ADJUSTMENT 37 MOTOR AND SUCTION FAN DISASSEMBLY ASSEMBLY 39 SUCTION HOSE DISASSEMBLY ASSEMBLY 41 DUST CONTROL SYSTEM 43 DESCRIPTION 43 TROUBLESHOOTING 44 NOZZLE AND FILTER CLEANING 45 WATER FILTER CLEANING 47 WATER TANK EMPTYING 48 STEERING SYSTEM 49 DESCRIPTION 49 TROUBLESHOOTING 50 REAR A...

Page 4: ... HYDRAULIC DIAGRAM 101 TROUBLESHOOTING 103 HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK 104 HYDRAULIC SYSTEM OIL CHANGE 105 HYDRAULIC SYSTEM OIL SUCTION FILTER REPLACEMENT 107 HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT 108 DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT 109 HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK 110 REAR WHEEL CONTROL HYDRAULIC CYLINDER DISASSEMBLY ASSEMBLY 111...

Page 5: ... to follow these instructions may cause damage to the machine OTHER AVAILABLE MANUALS The following Manuals are available at Nilfisk Literature Service Department RS 501 Spare Parts List Nilfisk Form Number 33015502 RS 501 User Manual Nilfisk Form Number 33015501 SAFETY The following symbols indicate potentially dangerous situations Always read this information carefully and take all necessary pre...

Page 6: ...uel is highly flammable Do not smoke or bring naked flames in the area where the machine is refuelled or where the fuel is stored Refuel outdoors or in a well ventilated area with the engine off Do not fill the fuel tank to the top but leave at least 4 cm from the filler neck to allow the fuel to expand After refuelling check that the filler cap is tightly closed If any fuel is spilled while refue...

Page 7: ...NAL spare parts from an authorised Dealer or Retailer The machine must be disposed of properly because of the presence of toxic harmful materials batteries etc which are subject to standards that require disposal in special centres see the Scrapping chapter While the engine is running the silencer heats up Do not touch the silencer to avoid serious scalding or fire Do not run the engine if the oil...

Page 8: ...ator 1 500 Kg Performance data Values Maximum forward speed for transport only 20 km h Maximum working speed 12 km h Maximum reverse speed 8 km h Gradeability at full load 22 30 optional Minimum inner turning radius 2 46 m Maximum side broom speed 80 rpm Collection system Suction Cleaning width 1 600 mm Filtering system Metallic net Sound pressure level at workstation ISO EN 3744 at maximum workin...

Page 9: ... point in solution with 50 water C 110 FF SS cat 002 132 Freezing point in solution with 50 water C 38 ASTM D 1384 Color Turquoise blue Density at 15 C kg l 1 13 See the engine oil technical data and reference data tables below SPECIFICATIONS REFERENCE DATA SAE QUALITY 15W40 ACEA E3 96 Viscosity at 100 C mm2 s 13 7 API Service CG 4 SG Viscosity at 40 C mm2 s 100 CCMC D5 PD 2 Viscosity at 15 C mm2 ...

Page 10: ...HSE Density at 15 C kg l 0 87 0 865 CETOP RP 91 H HV COMMERCIAL HYDRAULICS Danieli Standard 0 000 001 AGIP ARNICA 22 46 68 EATON VICKERS I 286 S3 EATON VICKERS M 2950 DIN 51524 t 3 HVLP LAMB LANDIS CINCINNATI P68 P69 and P70 LINDE PARKER HANNIFIN DENISON HF 0 REXROTH RE 90220 1 11 02 SAUER DANFOSS 520L0463 ENVIRONMENTAL CONDITIONS In the environment where the machine operates there must not be any...

Page 11: ...ours Every 1 200 hours Every 2 400 hours Long periods Engine oil level check Engine air filter cleaning Engine radiator fin cleaning check Engine coolant level check Battery fluid level check Hydraulic system oil level and drain filter efficiency check Hydraulic system oil cooler fin check and cleaning Hopper filter and suction hose cleaning and gasket check Dust control system nozzle and filter c...

Page 12: ...suction filter replacement Alternator belt replacement 3 Cab air filter replacement 1 Injector calibration and cleaning 2 3 Climate control system belt replacement Engine coolant change 3 Hydraulic system oil change 3 Brake system check Hydraulic system pump pressure check Minor engine overhaul 2 4 Major engine overhaul 2 5 1 Or every 6 months 2 Maintenance to be performed by Lombardini authorised...

Page 13: ...vation lever Cab heater control knob Diesel engine throttle lever Parking brake lever Broom dust control system nozzle valve Suction inlet dust control system nozzle valve Skirt lifting switch Lifted hopper warning light red Hazard warning light switch Dust control system switch Cab blower switch Windscreen wiper washer switch Climate control system switch Ignition key Dust control system water ta...

Page 14: ...ystem pump Hydraulic system pressure intake at suction fan pump Hydraulic system pressure intake at accessory and steering system pump 107 108 109 110 111 112 113 114 115 116 117 Hopper lid suction sealing gasket Document holder Hopper lifting lowering lever safety flange Suction inlet and broom lifting lowering lever safety flange Driver s seat forward backward adjustment lever Ashtray High press...

Page 15: ...L ENGLISH RS 501 33015500 3 2008 02 13 GENERAL INFORMATION MACHINE NOMENCLATURE Continues 99 100 19 18 7 8 2 11 10 1 103 104 45 17 102 26 9 15 9 16 8 21 24 20 13 6 3 101 113 25 97 98 110 112 111 115 12 14 4 S301479 ...

Page 16: ...LISH SERVICE MANUAL 14 33015500 3 2008 02 RS 501 GENERAL INFORMATION MACHINE NOMENCLATURE Continues 32 27 31 118 105 48 28 29 30 26 40 46 47 37 41 49 42 39 38 33 107 51 43 35 50 44 36 106 5 114 128 S301617 ...

Page 17: ...AL ENGLISH RS 501 33015500 3 2008 02 15 GENERAL INFORMATION MACHINE NOMENCLATURE Continues 123 120 121 66 61 59 65 69 63 122 56 53 55 68 108 58 62 67 57 54 60 64 109 23 34 124 125 126 119 52 22 127 116 117 S301481 ...

Page 18: ...ENGLISH SERVICE MANUAL 16 33015500 3 2008 02 RS 501 GENERAL INFORMATION MACHINE NOMENCLATURE Continues 80 79 81 77 71 73 74 72 96 76 70 1 78 85 86 87 88 89 82 83 84 90 95 94 93 92 91 75 S301407 ...

Page 19: ...rms C which are fastened to the machine frame Broom rotation is activated by hydraulic motors For proper sweeping and conveyance of dust and debris towards the suction inlet Broom height and tilting must be properly adjusted Proper brooms must be used according to the type of ground to be cleaned The following types are available Polypropylene brooms Polypropylene and steel brooms A B C C S300857 ...

Page 20: ...e not adjusted correctly adjust The broom speed is not correct adjust The brooms do not rotate Possible causes There are oil leaks from the hydraulic system hoses replace the hoses The hydraulic motors are faulty replace The accessory system hydraulic pump does not pressurize the oil in the circuit check the hydraulic system oil pressure 1 2 1 2 3 ...

Page 21: ...ever 66 Turn the ignition key 76 to OFF position and remove it Broom height adjustment On both sides of the machine operate on the tensioning self locking nut C of the spring D and consider the following To lower the broom the nut C must be unscrewed To lift the broom the nut C must be screwed Perform step 1 again Broom forward tilting angle adjustment On both sides of the machine loosen the screw...

Page 22: ...ENGLISH SERVICE MANUAL 20 33015500 3 2008 02 RS 501 SWEEPING SYSTEM SIDE BROOM POSITION CHECK AND ADJUSTMENT Continues S301482 ...

Page 23: ...les Lift the brooms and engage the parking brake with the lever 66 Turn the ignition key 76 to OFF position and remove it Remove the centre screw A then remove the broom B to be replaced Recover the key Remove the screws D then remove the flange E Install the flange E and secure it on the new broom with the screws D Install the new broom B with the key then tighten the centre screw A Adjust the he...

Page 24: ...un the engine at maximum speed and set the broom speed adjuster 127 to maximum speed as shown in the User Manual In this condition measure the broom speed with the portable tachometer Turn off the machine The broom speed must be 80 rpm If necessary change the broom speed according to the following procedure Speed adjustment Remove the screws and the right panel 22 in the cab To change the broom sp...

Page 25: ... control system allows for debris discharging Both the lid H and the suction hole I are equipped with gaskets which allow the suction inlet E to reach the maximum suction capacity Inside the hopper there are two stainless steel filters having the following functions The suction filter B retains dust and debris during fan suction phase and makes them settle in the hopper The breather filter N retai...

Page 26: ...ENGLISH SERVICE MANUAL 24 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM DESCRIPTION Continues D G E F C B N A H J K P K L M K I O Q S301483 ...

Page 27: ...ble causes The motor is faulty replace The control valve assembly is stuck repair The pump is faulty replace The suction inlet does not collect debris efficiently Possible causes The suction inlet position is incorrect check the suction inlet and skirt height and efficiency The skirt opening force is not sufficient Possible causes The skirt opening pressure is incorrect adjust The hopper does not ...

Page 28: ...heck the suction sealing gasket V for integrity and replace it if necessary Suction filter cleaning Inside the hopper remove the suction filter fastener A Remove the suction filter B Wash the deflector C and the fan D with pressurised water check that all fan sectors T are clean Clean the suction filter F with pressurised water from a hydrocleaner E Install the suction filter B and secure it with ...

Page 29: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 27 DUST AND DEBRIS COLLECTION SYSTEM HOPPER FILTER AND SUCTION HOSE CLEANING AND GASKET CHECK Continues A E F D C B U H G K L J I D T S300862 ...

Page 30: ...ENGLISH SERVICE MANUAL 28 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM HOPPER FILTER AND SUCTION HOSE CLEANING AND GASKET CHECK Continues N M P O V R S300863 ...

Page 31: ...uction inlet operation If necessary replace the skirt I see the procedure in the relevant paragraph Drive the machine on a level ground and lower the suction inlet 12 according to the procedure shown in the User manual Turn the ignition key 76 to OFF position and remove it Check that the distance L of the skirt from the ground is not bigger than 1 cm Greater distances can affect the suction inlet ...

Page 32: ...ENGLISH SERVICE MANUAL 30 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK Continues B H A D G C E F G A A L I K J F G O N S301484 ...

Page 33: ...e screws E and F then remove the front wheels A and B Install the new front wheels A and B and fasten them with the screws E and F If necessary perform the suction inlet and skirt height and operation check see the procedure in the relevant paragraph Front wheels A and B and rear wheel C removal installation Place the machine on the appropriate hoisting system if present and lift it If the hoistin...

Page 34: ...tem is not available remove the suction inlet assembly D see the procedure in the relevant paragraph Remove the mounting screws A and B then remove the sliding panels C D and E Install the new sliding panels C D and E and fasten them with the screws A and B Also check that when the wheels F contact the ground the sliding panels C D and E do not touch the ground otherwise the wheels F must be repla...

Page 35: ...and remove it Disconnect the hydraulic system hoses A and B from the suction inlet C and plug them Disconnect the dust control system water hose D Remove the nuts E and pins F Move the suction inlet C forward and loosen the suction hose clamp G Disconnect the suction hose H from the suction inlet Remove the suction inlet C Assembly Assemble the components in the reverse order of disassembly If nec...

Page 36: ...ual Engage the parking brake with the lever 66 Turn the ignition key 76 to OFF position and remove it Remove the clip A and the skirt B Remove the screws C then remove the skirt D Install the new skirt D and fasten it with the screws C Install the skirt B and the clip A Lift the suction inlet 12 according to the procedure shown in the User Manual B C D A S300868 1 2 3 4 5 6 7 8 ...

Page 37: ...s 29 Lower the hopper 3 according to the procedure shown in the User Manual and check that the profiles D match the frame profiles E If necessary perform steps 4 5 6 8 9 and 10 again Then perform steps 3 4 5 and tighten the locknuts A Lower the hopper 3 according to the procedure shown in the User Manual and check that the hopper suction hole F match the suction hose gasket G If necessary adjust t...

Page 38: ...ENGLISH SERVICE MANUAL 36 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM HOPPER POSITION ADJUSTMENT Continues F G I H J L D C B A D C B A E E S300869 ...

Page 39: ...he figure in this condition loosen the security dowel F of the cam G and then turn the cam until the microswitch H activates Open safety hook warning light adjustment When the safety hook D of the lid E is turned to closing position as shown in the figure loosen the security dowel I of the cam J and turn the cam until the corner K causes the microswitch L to activate and the warning light to turn ...

Page 40: ...ENGLISH SERVICE MANUAL 38 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM HOPPER LID CLOSING ACTUATOR ADJUSTMENT Continues F P Q G I N H L O D E K J S300965 ...

Page 41: ...on fan motor I Remove the mounting nuts J of the flange M With an appropriate hoisting system remove the suction fan motor assembly K by removing the silicone along the perimeter L of the flange M then sling the assembly K by placing a rope around the motor I and the fittings N At the workbench remove the screw O and the fan P Remove the nuts Q from the screws R Remove the motor I from the flange ...

Page 42: ...ENGLISH SERVICE MANUAL 40 33015500 3 2008 02 RS 501 DUST AND DEBRIS COLLECTION SYSTEM MOTOR AND SUCTION FAN DISASSEMBLY ASSEMBLY Continues O P R M J N G N H Q L K S301488 ...

Page 43: ...pen the right and left lids 20 and 18 by releasing the fasteners 21 and 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Disassembly Loosen the clamp A and disconnect the suction hose B from the suction inlet C Loosen the left and right side mounting screws D of the suction hose upper end E Remove the suction hose F by pulling it upwards Ass...

Page 44: ...ENGLISH SERVICE MANUAL 42 33016312 0 2007 04 RS 501 UK DUST AND DEBRIS COLLECTION SYSTEM ...

Page 45: ...room nozzles Suction inlet nozzles Water filter Hose Water level indicator Nozzle pump Taps Rear suction pipe nozzle Opening tap Tank drain plugs The water gun connected to the dust control system consists of Water gun pump Quick coupling Water gun Hose Reel Pressure gauge C I J D D E C H M K B A G F I J E E D D J N O P Q R O P S M B L F N A J K S301489 A B C D E F G H I J K L M N O P Q R S ...

Page 46: ...OL SYSTEM TROUBLESHOOTING No water from the nozzles Possible causes The water filter is clogged clean replace The nozzles are clogged clean No water to the nozzles Possible causes The water pump relay is burned replace The pump does not work repair replace 1 2 1 2 ...

Page 47: ...replace the filters C Install the filters and nozzles and secure them with the ring nuts Nozzle holes must be directed down when tightening Cleaning of nozzles inside the suction inlet On both sides of the suction inlet D remove the screws E together with the nozzles F Clean the nozzles F and screws E with compressed air Remove calcium deposits Assemble the components in the reverse order of disas...

Page 48: ...ENGLISH SERVICE MANUAL 46 33015500 3 2008 02 RS 501 DUST CONTROL SYSTEM NOZZLE AND FILTER CLEANING Continues F D E F E G H I A A B C S301490 ...

Page 49: ...ter inside the tanks comes out up to the filter level Preliminary operations Turn the ignition key 76 to OFF position and remove it Engage the parking brake with the lever 66 In the area over the rear axle 15 remove the water filter cover A together with the filter B Separate the filter B from the cover A then wash and clean it If necessary replace the filter B Install the filter B and the cover A...

Page 50: ...pty the dust control system water tanks 7 and 16 according to the following procedure Turn the ignition key 76 to OFF position and remove it Engage the parking brake with the lever 66 Remove the water tank drain plugs A and B and drain all the water from the tanks Install the plugs A and B A B S301492 1 2 3 4 ...

Page 51: ...tivates the steering gearbox which controls an hydraulic cylinder that operates on the rear wheels assembled on a steering axle The steering system consists of Oil pump Priority valve Steering gearbox Rear wheel control hydraulic cylinder Hydraulic system oil tank Hydraulic system hoses C B A E F D S300878 A B C D E F ...

Page 52: ...NG The machine does not move straightforward Possible causes The rear axle toe in is incorrect adjust The steering is hard Possible causes The steering gearbox is faulty replace The priority valve is faulty replace The rear wheel control hydraulic cylinder is faulty replace 1 1 2 3 ...

Page 53: ...er than the wheel diameter Place the plates B on the external surface of the wheels A at the centre of the wheels and parallel to the ground as shown in the figure Do not place the plates B where the tire surface is irregular Keeping the plates B in the above mentioned position check that the distances E and F measured on the front and on the back of the wheels A are the same A maximum difference ...

Page 54: ...ENGLISH SERVICE MANUAL 52 33015500 3 2008 02 RS 501 STEERING SYSTEM REAR AXLE TOE IN ADJUSTMENT Continues D C C D S300880 ...

Page 55: ...e drum brakes of the front wheels The brake system consists of Brake pedal Brake fluid pump Hydraulic system oil tank Cylinders Pipes Drum brakes The parking brake is mechanic manually controlled and actuates on the drum brakes of the front wheels The parking brake consists of Parking brake lever Bracket Control cable Drum brakes G C A E B E E I I H D F D F S300881 A B C D E F G H I J ...

Page 56: ...Possible causes The brake fluid is insufficient check the fluid level The brake fluid pump is faulty overhaul There is air in the system bleed The drum brake cylinder is faulty replace The braking masses are worn or greasy replace The parking brake is not efficient Possible causes The brake is misadjusted adjust 1 2 3 4 5 1 ...

Page 57: ...with the lever 66 Turn the ignition key 76 to OFF position and remove it Open the right lid 20 Check that the fluid level in the tank A is approximately at 1 cm from the filler neck If necessary top up using the same type of fluid that is in the line Type of fluid used DOT4 Close the right lid 20 A S301618 1 2 3 5 ...

Page 58: ...7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Operating under the parking brake lever 66 adjust the brake control cables according to the following procedure depending on the type of adjustment same adjustment for both wheels or...

Page 59: ...open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Operating under the parking brake lever 66 unscrew the locknuts C and D disconnect the control cable E or F and recover the relevant spring G Remove the front wheel see the procedure in the relevant paragraph Place safety stands under the machine side sill Remove the screw ...

Page 60: ...ENGLISH SERVICE MANUAL 58 33015500 3 2008 02 RS 501 BRAKE SYSTEM PARKING BRAKE CONTROL CABLE REPLACEMENT Continues H I K L P M N L L N M O S300885 ...

Page 61: ...ure in the relevant paragraph Press the brake pedal 57 several times and check that brakes operate properly Check that there are no leaks from the brake system If necessary check replace the brakes see the procedure in relevant paragraph If necessary bleed the brake system see the procedure in the relevant paragraph 1 2 3 4 5 ...

Page 62: ... sill on the side where the wheel has been removed Remove the screw A and the screws B then remove the washer C Remove the drum D Remove the three springs E Remove the shoe retaining springs F Remove the shoes G together with the braking masses by disengaging the parking brake control cable H from the lever I Perform steps 1 to 7 in the reverse order C A B D E I F G E E G F H S300886 1 2 3 4 5 6 7...

Page 63: ...side sill on the side where the wheel has been removed Remove the brake system bleed valve plug A and connect the pipe B to bleed the fluid Press the brake pedal 57 until the pedal resistance increases In this condition keep the pedal pressed and unscrew the valve A slightly Let the oil and air bleed from the pipe B into the container C until no more air comes out but oil only Then screw down the ...

Page 64: ...ENGLISH SERVICE MANUAL 62 33016312 0 2007 04 RS 501 UK BRAKE SYSTEM ...

Page 65: ...ve pedal controls two independent drive system hydraulic motors applied to the front wheels Front and rear wheels are pneumatic The drive system consists of Drive pedal Right drive system motor Left drive system motor Drive system pump Hydraulic system oil tank Hoses C B A E F D S300878 A B C D E F ...

Page 66: ...are worn replace The drive pedal is faulty replace The drive system pump power decreases check the oil pressure at the drive system pump The machine does not move Possible causes The drive system pump deactivation screw for machine pushing towing is unscrewed screw down There are oil leaks from the hydraulic system repair The drive system pump is broken replace The drive system motor is broken rep...

Page 67: ...0 3 2008 02 65 DRIVE SYSTEM TIRE PRESSURE CHECK Engage the parking brake with the lever 66 Turn the ignition key 76 to OFF position and remove it The tire pressure should be as follows Front tires 3 75 Bar Rear tires 3 75 Bar S301511 1 2 3 ...

Page 68: ...Check that the surface A of the sensor B is flush with the surface C of the drive pedal If necessary loosen the sensor mounting nut D and adjust the sensor position When the adjustment is completed tighten the nut D Check that the distance between the sensor surface A and the bracket E is within 1 5 and 2 5 mm When checking move the drive pedal F towards the bracket E to cancel the drive pedal end...

Page 69: ...of the cab Disconnect the reverse gear buzzer activation sensor connector B Remove the four mounting screws D of the drive pedal E Slightly lift the drive pedal E and remove the mounting nut F of the sensor C Remove the sensor C the harness G and the connector Assembly Assemble the components in the reverse order of disassembly Adjust the reverse gear buzzer activation sensor see the procedure in ...

Page 70: ...rear axle B as shown in the figure Carefully activate the jack A and lift the wheel C until it is slightly detached from the ground Remove the mounting nuts then remove the wheel C Install the wheel C by performing steps from 5 to 7 in the reverse order Wheel mounting nut tightening torque 400 N m Front wheel removal installation Place the jack E not equipped under the relevant housing F on the ma...

Page 71: ...ly Remove the right or left nut E then disconnect the parking brake control cable C from the bracket D Disconnect the hoses F from the drive system motor B and plug them immediately Remove five screws G then remove the drive system motor B together with the brake Assemble the components in the reverse order of disassembly and note the following Before assembling the wheel bleed the brake system se...

Page 72: ...afety stands under the machine side sill on the side where the wheel has been removed Lift the hopper 3 for 20 cm according to the procedure shown in the User Manual Turn the ignition key 76 to OFF position and remove it Open the right lid 20 by releasing the fasteners 21 with the supplied key Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant parag...

Page 73: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 71 DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT Continues A B C D E S301494 ...

Page 74: ...ENGLISH SERVICE MANUAL 72 33016312 0 2007 04 RS 501 UK DRIVE SYSTEM ...

Page 75: ...esel engine data see the Technical Data chapter and the Diesel Engine Manual The following pumps are connected to the engine Accessory and steering system pump Suction fan pump Drive system pump The fuel filter is located on the machine frame For machines equipped with climate control system besides the alternator control pulley there is also the compressor control pulley D A B C D S301413 A B C ...

Page 76: ...2 ENGINE TROUBLESHOOTING The diesel engine does not start Possible causes The drive pedal is pressed release The sensor for engine start up inhibition is misadjusted broken adjust replace NOTE For diesel engine complete troubleshooting see the relevant Manual 1 2 ...

Page 77: ...ove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 49 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Check the oil level according to the procedure shown in the Di...

Page 78: ...easing the fasteners 21 and 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Chang...

Page 79: ...it Open the left lid 18 by releasing the fasteners 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of wat...

Page 80: ...g the fasteners 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 WARNING The coolant line is pressurised do not perform any check until the engine has cooled down and even if the engine is cold the tank plug B must be opened with extreme care Check that the coolant level in the tank A is between the minimum and maximum marks according to the...

Page 81: ...8 by releasing the fasteners 19 with the supplied key Pre filter cleaning Remove the screw A then remove the pre filter B Clean and wash the pre filter then install it Filter cleaning Remove the screw C then remove the cover D Remove the outer filter E and the inner filter F Clean the filters E and F carefully with compressed air maximum 6 Bar and replace them if necessary Install the filters E an...

Page 82: ...he fasteners 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Replace the fuel filt...

Page 83: ...sings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Operating on the fuel filter A and on the diesel engine check the sealing of fuel system fittings ...

Page 84: ...1 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Check and if necessary adjust the ...

Page 85: ...rs 21 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Replace and adjust the alterna...

Page 86: ...ith the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph On both sides of the machine loosen the screws 42 and 44 and open the right and left tanks 41 and 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of wat...

Page 87: ...asteners 21 and 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screws 44 and 42 and open the right 43 and left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximate...

Page 88: ...g the fasteners 21 and 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Change the ...

Page 89: ...he fasteners 19 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Calibrate and clean t...

Page 90: ...ENGLISH SERVICE MANUAL 88 33016312 0 2007 04 RS 501 UK LDW 1603 B2 ENGINE ...

Page 91: ...CRIPTION The climate control system consists of Compressor Condenser Cooler Expansion valve Filter drier High pressure hose Low pressure hose High pressure connection Low pressure connection Cooling controls Heating controls Heater Air filter M C D G I A F H B E L K J S300899 A B C D E F G H I J K L M ...

Page 92: ... compressor does not turn because the drive belt is loosen broken tension replace the belt There are gas leaks from the system repair the leak and integrate the gas The expansion valve is faulty replace No hot air from the climate control system Possible causes The hot water hoses are broken replace There are water leaks from the heater replace 1 2 3 1 2 ...

Page 93: ... holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Check the tension of the belt A of the compressor B according to the following procedure Press the belt in the intermediate posit...

Page 94: ...the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 42 and open the left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Loosen the tensioning nuts A of the belt B of the compressor C Remove the belt B from the p...

Page 95: ... the ignition key 76 to OFF position and remove it Remove the screws A and the panel B in the cab Unscrew the knobs F and remove the panel C Remove the cab air filter D Install the new filter D with the arrows E pointing in the direction of the air flow upwards Perform steps 3 and 4 in the reverse order D E A A A A F C F B S300902 1 2 3 4 5 6 7 ...

Page 96: ...ENGLISH SERVICE MANUAL 94 33016312 0 2007 04 RS 501 UK CLIMATE CONTROL SYSTEM ...

Page 97: ...e locking pins 28 from the housings 29 and place them into the holes 30 Empty the dust control system water tanks 7 and 16 according to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Remove the screw 42 and open the left tank 41 Inspect the machine a...

Page 98: ...g brake with the lever 66 Turn the ignition key 76 to OFF position and remove it Lubricate the rear axle knuckles with the grease nipples A If necessary steer the rear wheels to reach the grease nipples easily Grease quantity to be applied 2 3 pumping in case of a manual pump 8 12 seconds of injection in case of an air pump A A A A S300903 1 2 3 ...

Page 99: ... OFF position and remove it Check that the surface A of the sensor B is flush with the surface C of the drive pedal If necessary loosen the sensor mounting nut D and adjust the sensor position When the adjustment is completed tighten the nut D Check that the distance between the sensor surface A and the bracket E is within 1 5 and 2 5 mm When checking move the drive pedal F towards the bracket E t...

Page 100: ...nder the right side of the cab Disconnect the connector B of the sensor for engine start up inhibition C Remove the four mounting screws D of the drive pedal E Slightly lift the drive pedal E and remove the mounting nut F of the sensor C Remove the sensor C the harness G and the connector Assembly Assemble the components in the reverse order of disassembly Adjust the sensor for engine start up inh...

Page 101: ...ear wheel control hydraulic cylinder activation by means of the oil taken from the priority valve All circuits are protected by suction filters and safety valves NOTE The hydraulic system hoses are DIN type COMPONENT LOCATION Hydraulic system oil tank Drain filter Suction filter Suction filter Drive system pump Diesel engine Left drive system motor Control valve assembly Right drive system motor S...

Page 102: ...GLISH SERVICE MANUAL 100 33015500 3 2008 02 RS 501 HYDRAULIC SYSTEM COMPONENT LOCATION Continues 57 76 69 52 53 64 75 81 61 51 79 60 65 70 54 78 55 80 58 73 72 74 71 68 59 63 56 62 67 66 65 82 50 S301619 ...

Page 103: ...m oil cooler Parachute valve Suction inlet and broom lifting cylinder Check valve Power steering Flow separator priority valve Accessory and steering system pump Suction fan pump Control valve assembly Solenoid valve Suction fan motor Power steering cylinder Drive pedal assist Oil filter Drive system pump oil filter High pressure washing system pump Flow regulator Breather filler plug Optional for...

Page 104: ...Y 58 lt 15 32 U S gal 40cc 18bar 90bar 21cc 11 23cc 14 1cc 210bar 58 8 7 l min 13 1 l min 150bar 150bar Versione B B Version 175cc Standard 250bar 250bar Versione C C Version 200cc 2600 RPM MAX 76 75 51 60µm 10µm 79 ASPIRAZIONE ACQUA WATER INLET USCITÀ ACQUA WATER OUTLET C1 C2 B A 78 T P B A 1 3 2 80 P T B1 A1 A 1 2 3 4 P B2 A2 1 0 2 1 3 2 1 1 1 1 9cc A B M1 M2 L1 T P R L A A A A A A A A A P1 L2 A...

Page 105: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 103 HYDRAULIC SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the hydraulic system ...

Page 106: ... indicator D of the drain filter C is in the green area E otherwise the filter C must be replaced see the procedure in the relevant paragraph Check that there are no oil leaks in the upper area F of the hydraulic system oil tank Turn the ignition key 76 to OFF position and remove it Using the indicator A check that the oil level in the tank is between the MIN and MAX marks If necessary unscrew the...

Page 107: ...en unscrew the plug A drain the oil and collect it into an appropriate container WARNING Hydraulic system oil is highly corrosive wear rubber gloves CAUTION The hydraulic system oil should be disposed of properly according to the environmental Laws in force Unscrew and remove the filler plug B If necessary replace the drain filter C see the procedure in the relevant paragraph Screw down the plug A...

Page 108: ...ENGLISH SERVICE MANUAL 106 33015500 3 2008 02 RS 501 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL CHANGE Continues A E S301621 ...

Page 109: ...uction filters C inside the tank WARNING Hydraulic system oil is highly corrosive wear rubber gloves CAUTION The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in force Remove any debris and dirt from the tank Clean the tank upper perimeter edge F and the matching profile D of the cover B Install the new filters C inside the tank Install the tan...

Page 110: ...nd remove it Open the right lid 20 by releasing the fasteners 21 with the supplied key Unscrew and remove the cover A WARNING Hydraulic system oil is highly corrosive wear rubber gloves CAUTION The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in force Remove the drain filter B and replace it with a new one Install the cover A Close the right l...

Page 111: ...cording to the procedure shown in the relevant paragraph Remove the screw 44 and open the right tank 43 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Remove the screw A and the filter B behind the right front wheel If necessary to reach the filter remove the right front wheel according to the procedure shown in the relevant paragraph WARNIN...

Page 112: ...rking brake with the lever 66 Lift the hopper 3 according to the procedure shown in the User Manual Turn the ignition key 76 to OFF position and remove it Open the right lid 20 by releasing the fasteners 21 with the supplied key Remove the locking pins 28 from the housings 29 and place them into the holes 30 Clean the hydraulic system oil cooler fins A with compressed air maximum 6 Bar If necessar...

Page 113: ...t Disconnect the hoses A from the rear wheel control hydraulic cylinder B and plug them immediately Unscrew the fasteners C fixing the cylinder to the steering tie rods Remove the screws D then remove the cylinder B Install the cylinder performing steps from 3 to 5 in the reverse order Adjust the rear axle toe in see the procedure in the relevant paragraph Check the hydraulic system oil level see ...

Page 114: ...the hydraulic system oil level and if necessary top up as shown in the User Manual Disassembly assembly of the following hydraulic cylinder Hopper lifting cylinder D Empty the hopper 3 if it contains a small quantity of waste it is not necessary to dump it Drive the machine on a solid and level ground then engage the parking brake with the lever 66 Lift the hopper 3 according to the procedure show...

Page 115: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 113 HYDRAULIC SYSTEM HYDRAULIC CYLINDERS DISASSEMBLY ASSEMBLY Continues A C B D S300913 ...

Page 116: ...n control valve assembly A and plug them immediately WARNING Hydraulic system oil is highly corrosive wear rubber gloves Loosen the locknut C and remove the lever B Remove the screws D then remove the control valve assembly A If necessary remove the fittings and the control valve assembly at the workbench Assemble the components in the reverse order of disassembly Check the hydraulic system oil le...

Page 117: ...tely WARNING Hydraulic system oil is highly corrosive wear rubber gloves Loosen the locknut C and remove the levers B Remove the screws D then remove the control valve assembly A If necessary remove the fittings and the control valve assembly at the workbench Assemble the components in the reverse order of disassembly Pour oil in the tank see the procedure in the relevant paragraph until the level...

Page 118: ...if they are empty each tank contains 120 kg of water approximately Remove the retaining clamps C of the exhaust manifold D then move the exhaust manifold Mark the position of the hoses connected to the fittings E of the accessory pump F for proper reassembly Disconnect the hoses from the fittings E of the accessory pump F and plug them immediately Collect the hydraulic system oil that comes out of...

Page 119: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 117 HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY ASSEMBLY LDW 1603 B2 engine Continues S300916 ...

Page 120: ...left tank 41 WARNING Open the tanks 7 and 16 only if they are empty each tank contains 120 kg of water approximately Mark the position of the hoses connected to the fittings E of the accessory pump F for proper reassembly Disconnect the hoses from the fittings E of the accessory pump F and plug them immediately Collect the hydraulic system oil that comes out of the hoses before plugging them WARNI...

Page 121: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 119 HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY ASSEMBLY LDW 1603 B2 engine Continues C C E G F G G G E S301423 ...

Page 122: ...Collect the hydraulic system oil that comes out of the hoses before plugging them WARNING Hydraulic system oil is highly corrosive wear rubber gloves Remove the screws C then remove the suction fan pump B with the joint D and the relevant fasteners If necessary remove the accessory pump joint D and fittings at the workbench Assemble the components in the reverse order of disassembly Start the mach...

Page 123: ...lect the hydraulic system oil that comes out of the hoses before plugging them WARNING Hydraulic system oil is highly corrosive wear rubber gloves Remove the screws E then remove the pumps B and C with the relevant joints If necessary remove the drive system pump fittings at the workbench If necessary remove the screws E then remove the suction fan pump C with the joint F and the relevant fastener...

Page 124: ...chine and run the engine at maximum speed as shown in the User Manual In this condition turn the lever F to OPT position and check that the pressure measured by the pressure gauge E is 220 Bar approximately If the pressure is normal disengage the lever F and turn off the machine If the pressure is higher or lower it can be adjusted according to the following procedure while keeping the machine acc...

Page 125: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 123 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP Continues H I C E F G S301500 ...

Page 126: ...to the following procedure Pressure measurement Start the machine and run the engine at maximum speed as shown in the User Manual In this condition engage the lever F to lift the hopper and check that the pressure measured by the pressure gauge E is 120 Bar approximately If the pressure is normal disengage the lever F and turn off the machine If the pressure is higher or lower it can be adjusted a...

Page 127: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 125 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP Continues G E C F H I S301501 ...

Page 128: ...ure gauge E with a minimum scale of 300 Bar equipped with the extension to the pressure intake B of the drive system pump Measure the drive system pump pressure according to the following procedure Pressure measurement Start the machine and run the engine at maximum speed as shown in the User Manual Fully engage the parking brake with the lever 66 WARNING To perform the inspection indicated in the...

Page 129: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 127 HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP Continues B A S301502 ...

Page 130: ...ENGLISH SERVICE MANUAL 128 33016312 0 2007 04 RS 501 UK HYDRAULIC SYSTEM ...

Page 131: ...0 A G1 Dust control system water level indicator G2 Fuel level indicator I1 Skirt lifting switch I2 Hazard warning light switch I3 Windscreen wiper washer switch I4 Water pump switch I5 Cab blower switch I6 Climate control system switch 2 speed 1 speed I7 Electric jack switch L1 Left front turn signal L2 Right rear turn signal L3 Right front turn signal L4 Left rear turn signal L5 Left brake light...

Page 132: ... 3 2008 02 RS 501 ELECTRICAL SYSTEM COMPONENT LOCATION Continues L15 EV2 EV3 L2 L6 L8 L16 C4 L10 L5 L4 M4 P M2 B7 M5 L1 L7 L11 L13 L3 M1 C6 K A B1 B2 B3 B5 G1 M6 L9 L12 L14 AA G2 B TM RS EV1 M8 AS M7 S301503 See the Diesel Engine Manual ...

Page 133: ...SERVICE MANUAL ENGLISH RS 501 33015500 3 2008 02 131 ELECTRICAL SYSTEM COMPONENT LOCATION Continues RY RX R7 R6 R4 R3 R1 D1 D2 R5 R2 I1 B4 B6 B8 BX M3 C2 S301504 ...

Page 134: ...33015500 3 2008 02 RS 501 ELECTRICAL SYSTEM COMPONENT LOCATION Continues F1A F2A F3A F4A F5A F6A F1B F2B F3B F4B F5B F6B S11 S9 I2 I5 S14 I3 S12 I4 S13 I7 S17 C1 S6 C3 S8 S7 S2 S5 S1 G2 C5 S10 S3 S4 S16 F7A F8A I6 S15 F7B S301505 ...

Page 135: ... switch I5 Cab blower switch I6 Climate control system switch 2 speed 1 speed I7 Electric jack switch L1 Left front turn signal L2 Right rear turn signal L3 Right front turn signal L4 Left rear turn signal L5 Left brake light L6 Right brake light L7 Left front running light L8 Right rear running light L9 Right front running light L10 Left rear running light L11 Left low beam L12 Right low beam L13...

Page 136: ... B3 S16 C3 G2 C4 30 87a R3 85 86 S5 B8 31 15 30 2 0 4 0 15 54 RD BK RD RD BU BK BN BK GY RD RD VT RD BK BN BK BK BN RD VT RD VT RD BK BU BK GY RD GY RD GY RD PK WH PK WH PK WH BK PK BK BK RD LIGHT PK LIGHT BU WH BK OG GN BK PK YE GY GN RD BK PK WH BK OG GN BK BN BK S301506 Continues to the next page Color code BK Black BU Blue BN Brown GN Green GY Grey OG Orange PK Pink RD Red VT Violet WH White Y...

Page 137: ... 0 II 1 L4 L1 L2 L3 L5 L6 7 S10 1 2 0 1 3 C2 R4 I2 3 4 6 1 2 8 5 S9 10 B6 AA C 1 31 15 30 31 15 30 15 54 4 2 2 2 BN BK PK YE PK BK BK PK YE BU BK BU WH YE WH RD WH GN YE GN YE RD OG OG RD BK BK WH OG BU WH BK BK OG LIGHT BU LIGHT BU BU BU BU BU BU YE RD RD RD BN BK YE YE YE GY YE VT YE RD GY YE GY YE YE RD GY YE GY YE BK BU S301506 Continues from the previous page Continues to the next page ...

Page 138: ... 7 4 2 9 II I 0 5 10 I4 3 I 0 5 87a 30 RS D2 I5 S13 0 2 1 D1 S14 F4A F3A C6 M6 TM R6 85 87 86 30 P R7 85 87 86 30 I6 2 5 1 2 I 0 3 6 S15 F7B AS 31 15 30 4 3 2 3 GY YE VT GY BK GY VT BK VT VT BK WH RD BU RD BU RD BK RD BK WH RD BK WH YE WH WH RD WH BU PK WH WH BU BU BK OG GN WH GY BK WH RD BK WH RD GY RD WH RD WH BN YE GN BK BK S301506 Continues from the previous page ...

Page 139: ...RS 501 33015500 3 2008 02 137 ELECTRICAL SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the electrical system Other possible causes The fuses are burnt replace The harness is cut or pressed repair 1 2 ...

Page 140: ...ning procedures Engage the parking brake with the lever 66 Turn the ignition key 76 to OFF position and remove it Remove the screws and the left panel 23 in the cab Check the electrolyte level in the battery A and if necessary top up If necessary clean the battery Check the battery terminal connections for oxidation Install the left panel 23 in the cab and the screws A S301507 1 2 3 4 5 6 7 ...

Page 141: ...ow beam fuse 15 A High beam fuse 15 A Cigarette lighter fuse 20 A Free fuse holder Fuse box A Hydraulic system oil cooler fan skirt solenoid valve fuse 20 A Fuel solenoid valve fuse 10 A Cab blower flashing light windscreen wiper fuse 15 A Dust control system water pump fuse 10 A Dust control system water pump climate control system optional fuse 20 A Reverse gear buzzer fuse 10 A Warning lights g...

Page 142: ...e cab Remove the suspected relay among the following General relay R2 Water pump relay R5 Reverse gear buzzer relay R3 Turn signal intermittence relay R4 Climate control system compressor relay R6 optional Condenser fan relay R7 optional Engine glow plug control unit relay R1 Engine start safety relay RX Engine start safety relay RY Assemble the components in the reverse order of disassembly C D C...

Page 143: ... 23 in the cab Disconnect the negative pin from the battery A Remove the screws C and lower the dashboard panel D in the cab Remove the screws E and lower the display F Disconnect the connectors G and H then recover the display F Install the new display by performing steps 6 and 7 in the reverse order Adjust the display by using the keyboard of tool no 33014099 connected to connectors I and J E I ...

Page 144: ...6 to OFF position and remove it Bulb replacement Remove the screws A and move the headlight B Replace the burned bulbs Install the headlight B and fasten it with the screws A Adjust the headlights according to the following procedure Low beam adjustment Use the screws C and D in the following way To adjust the beam vertically turn the screws C and D simultaneously To adjust the beam horizontally t...

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