Nilfisk RS 501 User Manual 2

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RS 501

ENGLISH SERVICE MANUAL

33015499(3)2008-02

SERVICE MANUAL

ENGLISH

TABLE OF CONTENTS

GENERAL INFORMATION .............................................................................................................................................. 3

MACHINE LIFTING ......................................................................................................................................................................... 3

MACHINE TRANSPORT ................................................................................................................................................................. 3

PUSHING OR TOWING THE MACHINE ......................................................................................................................................... 3

OTHER AVAILABLE MANUALS ...................................................................................................................................................... 3

SAFETY ........................................................................................................................................................................................... 3

GENERAL SAFETY INSTRUCTIONS ............................................................................................................................................. 4

TECHNICAL DATA ........................................................................................................................................................................... 6

ENVIRONMENTAL CONDITIONS ................................................................................................................................................... 8

MAINTENANCE ............................................................................................................................................................................... 9

SCHEDULED MAINTENANCE TABLE ........................................................................................................................................... 9

MACHINE NOMENCLATURE ........................................................................................................................................................11

SWEEPING SYSTEM .................................................................................................................................................... 17

DESCRIPTION .............................................................................................................................................................................. 17

TROUBLESHOOTING ................................................................................................................................................................... 18

SIDE BROOM POSITION CHECK AND ADJUSTMENT ............................................................................................................... 19

BROOM REPLACEMENT ............................................................................................................................................................. 21

BROOM SPEED ADJUSTMENT ................................................................................................................................................... 22

DUST AND DEBRIS COLLECTION SYSTEM .............................................................................................................. 23

DESCRIPTION .............................................................................................................................................................................. 23

TROUBLESHOOTING ................................................................................................................................................................... 25

HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK ........................................................................... 26

SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK ............................................................................................. 29

SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY ................................................................................................................ 31

SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY ............................................................................................... 32

SUCTION 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 AXLE TOE-IN ADJUSTMENT ............................................................................................................................................. 51

BRAKE SYSTEM ........................................................................................................................................................... 53

DESCRIPTION .............................................................................................................................................................................. 53

TROUBLESHOOTING ................................................................................................................................................................... 54

BRAKE FLUID LEVEL CHECK ...................................................................................................................................................... 55

PARKING BRAKE CHECK AND ADJUSTMENT ........................................................................................................................... 56

PARKING BRAKE CONTROL CABLE REPLACEMENT............................................................................................................... 57

BRAKE SYSTEM CHECK ............................................................................................................................................................. 59

BRAKING MASSES REPLACEMENT ........................................................................................................................................... 60

BRAKE SYSTEM BLEEDING ........................................................................................................................................................ 61

DRIVE SYSTEM ............................................................................................................................................................. 63

DESCRIPTION .............................................................................................................................................................................. 63

TROUBLESHOOTING ................................................................................................................................................................... 64

TIRE PRESSURE CHECK ............................................................................................................................................................ 65

REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR ADJUSTMENT ......................... 66

REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY ............................................................................................. 67

WHEEL REMOVAL/INSTALLATION .............................................................................................................................................. 68

DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY................................................................................................................ 69

DRIVE PEDAL CHECK AND ADJUSTMENT ................................................................................................................................ 70

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LDW 1603/B2 ENGINE .................................................................................................................................................. 73

DESCRIPTION .............................................................................................................................................................................. 73

TROUBLESHOOTING ................................................................................................................................................................... 74

ENGINE OIL LEVEL CHECK ......................................................................................................................................................... 75

ENGINE OIL CHANGE .................................................................................................................................................................. 76

ENGINE OIL FILTER CHANGE ..................................................................................................................................................... 77

ENGINE COOLANT LEVEL CHECK ............................................................................................................................................. 78

ENGINE AIR FILTER CLEANING .................................................................................................................................................. 79

FUEL FILTER REPLACEMENT ..................................................................................................................................................... 80

FUEL FITTING AND SCREW CHECK .......................................................................................................................................... 81

ALTERNATOR BELT TENSION CHECK ....................................................................................................................................... 82

ALTERNATOR BELT REPLACEMENT .......................................................................................................................................... 83

RADIATOR FIN CLEANING CHECK ............................................................................................................................................. 84

ENGINE COOLANT LINE SLEEVE CHECK ................................................................................................................................. 85

ENGINE COOLANT CHANGE ...................................................................................................................................................... 86

INJECTOR CALIBRATION AND CLEANING ................................................................................................................................ 87

CLIMATE CONTROL SYSTEM ..................................................................................................................................... 89

DESCRIPTION .............................................................................................................................................................................. 89

TROUBLESHOOTING ................................................................................................................................................................... 90

COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine) ............................................................................................... 91

COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine) .................................................................................................. 92

AIR FILTER REPLACEMENT ........................................................................................................................................................ 93

OTHER SYSTEMS ......................................................................................................................................................... 95

NUT AND SCREW TIGHTENING AND LEAKAGE CHECK .......................................................................................................... 95

LUBRICATION ............................................................................................................................................................................... 96

CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN

THE DRIVE PEDAL IS PRESSED ................................................................................................................................................ 97

DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN

THE DRIVE PEDAL IS PRESSED ................................................................................................................................................ 98

HYDRAULIC SYSTEM ................................................................................................................................................... 99

DESCRIPTION .............................................................................................................................................................................. 99

COMPONENT LOCATION ............................................................................................................................................................ 99

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

HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY ............................................................................................................112

SUCTION FAN CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION ...............................................................................114

ACCESSORY SYSTEM CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION .................................................................115

ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) .....................................116

SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY .................................................................................................................. 120

DRIVE SYSTEM PUMP DISASSEMBLY/ASSEMBLY................................................................................................................. 121

HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP ..................................................................... 122

HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP ............................ 124

HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP .......................................................................... 126

ELECTRICAL SYSTEM ............................................................................................................................................... 129

DESCRIPTION ............................................................................................................................................................................ 129

COMPONENT LOCATION .......................................................................................................................................................... 129

WIRING DIAGRAM ...................................................................................................................................................................... 133

TROUBLESHOOTING ................................................................................................................................................................. 137

BATTERY FLUID LEVEL CHECK ................................................................................................................................................ 138

FUSE REPLACEMENT ............................................................................................................................................................... 139

RELAY REPLACEMENT ............................................................................................................................................................. 140

CONTROL PANEL DISPLAY REPLACEMENT ........................................................................................................................... 141

LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT ............................................................................ 142

33015500(3)2008-02 RS 501

GENERAL INFORMATION

NOTE

Forward, backward, front, rear, left or right are intended with reference to the operator’s position, while on the driver’s seat.

MACHINE LIFTING

WARNING!

Do not work under the lifted machine without supporting it with safety stands.

MACHINE TRANSPORT

(See User Manual)

WARNING!

Before transporting the machine, make sure that:

All lids and covers are closed.

–

All moving parts are stopped.

–

The ignition key is removed.

–

The machine is securely fastened to the means of transport.

–

PUSHING OR TOWING THE MACHINE

WARNING!

When pushing or towing the machine, carefully follow the relevant instructions given in the User Manual. Failure to follow these instructions may cause damage to the machine.

SERVICE MANUAL

GENERAL INFORMATION

ENGLISH

OTHER AVAILABLE MANUALS

The following Manuals are available at Nilﬁ sk Literature Service Department: –

RS 501 Spare Parts List – Nilﬁ sk Form Number 33015502

–

RS 501 User Manual – Nilﬁ sk Form Number 33015501

SAFETY

The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary precautions to safeguard people and property.

DANGER!

It indicates a dangerous situation with risk of death for the operator.

WARNING!

It indicates a potential risk of injury for people or damage to objects.

CAUTION!

It indicates a caution related to important or useful functions. Pay careful attention to the paragraphs marked by this symbol.

NOTE

It indicates a remark related to important or useful functions.

CONSULTATION

It indicates that it is necessary to consult the User Manual before performing any procedure.

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GENERAL INFORMATION

GENERAL SAFETY INSTRUCTIONS

Speciﬁ c warnings and cautions to inform about potential damages to people and machine are shown below.

DANGER!

This machine must be used by properly trained and authorised personnel only.

–

Moreover, the operator must:

–

Be of full age

•

Have a driving license

•

Be in normal psycho-physical conditions

•

Not be under the effect of substances that alters the nervous system (alcohol, psycopharmaceuticals,

•

drugs, etc.)

Before performing any maintenance/repair procedure remove the ignition key, engage the parking brake

–

and disconnect the battery. Do not wear jewels when working near electrical components.

–

Do not work under the lifted machine without supporting it with safety stands.

–

When working under open hoods/lids, make sure that they cannot be closed by accident.

–

When performing maintenance procedures with the lifted hopper, apply the relevant support rods.

–

Do not operate the machine near toxic, dangerous, ﬂ ammable and/or explosive powders, liquids or vapors.

–

Be careful, fuel is highly ﬂ ammable.

–

Do not smoke or bring naked ﬂ ames 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 ﬁ ll the fuel tank to the top, but leave at least 4 cm from the ﬁ ller neck to allow the fuel to expand.

–

After refuelling, check that the ﬁ ller cap is tightly closed.

–

If any fuel is spilled while refuelling, clean up the affected area and allow the vapors to dissipate before

–

starting the engine. Avoid contact with skin and do not breathe in fuel vapors. Keep out of reach of children.

–

Do not tilt the engine too much to avoid fuel spillage.

–

During machine transportation, the fuel tank must not be full.

–

WARNING!

Carbon monoxide (CO) can cause brain damage or death. The internal combustion engine of this machine can emit carbon monoxide. Do not inhale exhaust gas fumes. Only use indoors when adequate ventilation is provided, and when an assistant has been instructed to look after you.

Do not lay any object on the engine.

–

Before working on the engine turn it off. To prevent the engine from starting accidentally, disconnect the

–

battery negative terminal. See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this

–

Manual.

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GENERAL INFORMATION

WARNING!

Carefully read all the instructions before performing any maintenance/repair procedure.

–

Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by the machine

–

moving parts. Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using

–

compressed air or water gun. Avoid contact with battery acid, do not touch hot parts.

–

Do not leave the machine unattended with the ignition key inserted and the parking brake deactivated.

–

Do not remove or modify the plates afﬁ xed to the machine.

–

To drive on public roads, the machine must follow local licensing requirements.

–

The machine has been designed to be used as a sweeper, do not use it for different purposes.

–

In case of part replacement, order ORIGINAL 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

–

ﬁ re. Do not run the engine if the oil level is low, to avoid damaging it seriously. Check the oil level with the

–

engine off and the machine on a level surface. Do not run the engine if the air ﬁ lter is not installed, to avoid damaging it.

–

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 must be opened with extreme care. Only use original spare parts or parts of matching quality for the diesel engine. Using spare parts of lower

–

quality can seriously damage the engine. See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this

–

Manual.

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GENERAL INFORMATION

TECHNICAL DATA

Dimensions and weights Values

Machine length (broom bristles not included) 3,065 mm Machine width (broom bristles not included) 1,315 mm Distance between front and rear wheels 1,475 mm Front wheel base 930 mm Rear wheel base 840 mm Machine height 1,997 mm Minimum distance from the ground (skirts not included) 90 mm Maximum front working angle 18° Maximum dumping height 1,460 mm Front tires R165/70 R14C 89R Rear tires R165/70 R14C 89R Tire pressure 3.75 Bar Standard side broom diameter 720 mm Optional side broom diameter 650 mm Total machine weight, in running condition (without operator) 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 working speed 82 dB(A) Certiﬁ ed sound power (2000/14/EC) at maximum working speed 108 dB(A) Measured sound power (ISO/EN 3744) at maximum working speed 106 dB(A) Hopper capacity 500 liters Hopper maximum load 380 Kg Dust control By water Dust control system tank total capacity (No. 2) 240 liters Lighting and signalling system Road type Transmission Hydrostatic servoassisted Steering system On the rear axle, power assisted Brake Hydraulic Parking brake Mechanic Controls Hydraulic

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GENERAL INFORMATION

LDW 1603/B2 diesel engine data (*) Values

Make Lombardini Type LDW 1603/B2 Cylinders 3 Maximum speed 2,600 rpm Maximum working speed 2,200 rpm Maximum power at 2,600 rpm 25 kW Idle speed 900 rpm Consumption while operating at 2,200 rpm 5.0 L/h Consumption while operating at 2,600 rpm 5.9 L/h Engine coolant 50% antifreeze AGIP and 50% water (**) Engine oil type AGIP Sigma Turbo 15W/40 (***)

(*) For other diesel engine data/values, see the relevant Manual. (**) See the coolant technical data and reference data tables below.

SPECIFICATIONS REFERENCE DATA

Boiling point °C 170 CUNA NC 956-16 97 Boiling 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 /

Density at 15°C kg/l 1.13

(***) See the engine oil technical data and reference data tables below.

Turquoise blue

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/s 3,300 US Department of the Army MIL-L-2104 E Viscosity index / 138 US Department of the Army MIL-L-46152 E Flash point COC °C 230 MACK EO-L Pour point °C -27 MAN M 3275 Density at 15°C kg/l 0.885 Mercedes Benz 228.3

VOLVO VDS2 MTU typ 2

Refuelling data Values

Fuel tank capacity 30 liters Hydraulic system oil tank capacity 40.6 liters Hydraulic system capacity 58 liters

Electrical system data Values

System voltage 12 V Starting battery 12 V – 80 Ah

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GENERAL INFORMATION

Hydraulic system data Values

Maximum drive system pressure 250 Bar Maximum accessory system pressure 120/200 Bar Hydraulic system oil type (at ambient temperature above 10°C) AGIP Arnica 46 (****)

NOTE

If the machine is to be used at ambient temperatures below 10°C, the oil should be replaced with equivalent oil having a viscosity of 32 cSt. For temperatures below 0°C, use oil with lower viscosity.

(****) See the below hydraulic system oil technical data and reference data tables.

TECHNICAL DATA REFERENCE DATA

AGIP ARNICA 46 32 ISO-L-HV Viscosity at 40°C mm2/s 45 32 ISO 11158 Viscosity at 100°C mm Viscosity index / 150 157 AISE 127 Flash point COC °C 215 202 ATOS Tab. P 002-0/I Pour point °C -36 -36 BS 4231 HSE Density at 15°C kg/l 0.87 0.865 CETOP RP 91 H HV

/s 7.97 6.40 AFNOR NF E 48603 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 danger of explosion. To avoid inhaling exhaust gas, the machine must be used only where there is a proper air change. The machine operates correctly (*) in the following environmental conditions:

Temperature: -10°C to +40°C

–

Humidity: 30% to 95%, not condensed

– Store the machine indoor, in a clean and dry place, protected from bad weather conditions and with the following values:

Temperature: +1°C to +50°C

–

Humidity: maximum 95%, not condensed

–

(*) When using the sweeper at a temperature between -10°C and 0°C the dust control system cannot be used; moreover the

water tanks and the dust control system itself must be empty.

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GENERAL INFORMATION

MAINTENANCE

The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.

WARNING!

See GENERAL INFORMATION and SAFETY paragraphs.

The following table provides the scheduled maintenance. The intervals shown may vary according to particular working conditions, which are to be deﬁ ned by the person in charge of the maintenance. The instructions relating to the maintenance procedures given in the following table are described in the next paragraphs.

SCHEDULED MAINTENANCE TABLE

Maintenance

Engine oil level check

Engine air ﬁ lter cleaning

Engine radiator ﬁ n cleaning check

Engine coolant level check

Battery ﬂ uid level check

Hydraulic system oil level and drain ﬁ lter efﬁ ciency check

Hydraulic system oil cooler ﬁ n check and cleaning

Hopper, ﬁ lter and suction hose cleaning, and gasket check

Dust control system nozzle and ﬁ lter cleaning

Brake ﬂ uid level check

Reverse gear buzzer operation check

Diesel engine start-up safety system check

Tire pressure check

Suction inlet and skirt height and operation check

Running-in

period (after the

ﬁ rst 50 hours)

Every 10 hours or

before use

Every

200

hours

Every

600

hours

Every

1,200

hours

Every

2,400

hours

Long

periods

Side broom position check and adjustment

Engine oil change (7)(8)

Dust control system water ﬁ lter cleaning

Parking brake check

Alternator belt tension check (7)

Climate control system compressor belt tension check

Diesel engine oil ﬁ lter replacement (7)(8)

Fuel ﬁ lter replacement (7)

Nut and screw tightening and leakage check

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GENERAL INFORMATION

Maintenance

Lubrication

Engine coolant line sleeve check (7)

Drive system pump oil ﬁ lter check

Hydraulic system oil drain ﬁ lter replacement

Hydraulic system oil suction ﬁ lter replacement

Alternator belt replacement (3)

Cab air ﬁ lter 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)

Running-in

period (after the

ﬁ rst 50 hours)

Every 10 hours or

before use

Every

200

hours

Every

600

hours

Every

1,200

hours

Every

2,400

hours

Long

periods

(1) Or every 6 months (2) Maintenance to be performed by Lombardini authorised Service Center (3) Or every two years (4) After 5,000 hours (5) After 10,000 hours (7) Every year, if the machine is not frequently used (8) If a lower-quality oil is used, change it every 125 hours

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GENERAL INFORMATION

MACHINE NOMENCLATURE

Throughout this Manual you will ﬁ nd numbers in brackets, for example: (2). These numbers refer to the components indicated in these two nomenclature pages. Refer to these pages whenever it will be necessary to identify a component mentioned in the text.

Cab

1. Left door

2. Hopper

3. Diesel engine

4. Suction fan

5. Flashing light

6. Dust control system left tank

7. Front ﬁ xed wheels

8. Rear steering wheels

9. Right side broom

10. Left broom

11. Suction inlet

12. Right door

13. Meter and control panel

14. Rear axle

15. Dust control system right tank

16. Rear suction pipe (*)

17. Left lid

18. Left lid fasteners

19. Right lid

20. Right lid fasteners

21. Cab right panel

22. Cab left panel

23. Right door handle

24. Left door handle

25. Hopper lid

26. Open lid support rod

27. Lifted hopper locking pins

28. Lifted hopper locking pins housing

29. Lifted hopper locking pins holes

30. Suction ﬁ lter

31. Drain ﬁ lter

32. Hydraulic system oil tank

33. Battery

34. Hydraulic system oil cooler

35. Suction inlet-to-hopper pipe

36. Fuel tank

37. Hopper manual lifting hand pump (to be used in case of

38. engine malfunction) Hydraulic system oil drain ﬁ lter

39. Hopper lifting device

40. Dust control system left tank

41. Left tank mounting screw

42. Dust control system right tank

43. Right tank mounting screw

44. Front towing hook

45. Engine air ﬁ lter

46. Fuel tank ﬁ ller neck

47. Hopper support rods

48. Left water tank ﬁ ller plug

49. Right water tank ﬁ ller plug

50. Brake ﬂ uid tank

51. Windscreen wiper ﬂ uid tank

52. Windscreen wiper motor

53. Combination switch

54. Steering wheel adjusting lever

55. Drive pedal

56. Brake pedal

57. Steering wheel

58. Driver’s seat

59. Suction inlet and brooms control lever

60.

61.

Driver’s seat safety belt (*)

62.

Hopper lifting/lowering lever

63.

Suction activation lever

64.

Cab heater control knob

65.

Diesel engine throttle lever

66.

Parking brake lever

67.

Broom dust control system nozzle valve

68.

Suction inlet dust control system nozzle valve

69.

Skirt lifting switch

70.

Lifted hopper warning light (red)

71.

Hazard warning light switch

72.

Dust control system switch

73.

Cab blower switch

74.

Windscreen wiper/washer switch

75.

Climate control system switch (*)

76.

Ignition key

77.

Dust control system water tank warning light (red)

78.

Warning buzzer (it activates together with the warning lights 87, 91, 93, 94)

79.

Fuse box B

80.

Fuse box A

81.

Indicators and warning lights

82.

Optional indicator light

83.

Optional indicator light

84.

Engine coolant temperature

85.

High beam indicator light

86.

Running light indicator light

87.

Charged battery indicator light (together with the indicator light a buzzer activates with intermittent sound)

88.

Parking brake indicator light (together with the indicator light a buzzer activates with continuous sound)

89.

Glow plug pre-heating warning light

90.

Hour counter/revolution counter display:

•

It displays the hours, when the ignition key (76) is turned on the ﬁ rst position, before running the engine;

•

It displays the engine speed, when the engine is running and the charged battery warning light is off.

91.

Low fuel warning light (a buzzer activates together with the warning light)

92.

Optional indicator light

93.

Engine coolant high temperature warning light (a buzzer activates together with the warning light)

94.

Engine oil pressure warning light (a buzzer activates together with the warning light)

95.

Turn signal indicator light

96.

Hopper lid opening/closing switch

97.

Rear bumper Diesel engine serial number/technical data plate (another

98. plate showing the same data as the plate afﬁ xed on the diesel engine)(*) High-pressure washing system hose with reel (*)

99. High-pressure water quick coupling (*)

100. Breather ﬁ lter hood fasteners

101. Rear suction pipe fastener

102. Front skirt

103. Machine serial number

104. Hopper (dumping position)

105. Suction hose gasket

106.

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GENERAL INFORMATION

Hopper manual lifting hand pump lever

107. High-pressure water gun

108. Serial number plate/technical data/certiﬁ cation marking

109. Right water tank drain plug

110. Left water tank drain plug

111. High-pressure washing system pressure gauge

112. Breather ﬁ lter hood

113. Hydraulic system oil ﬁ ller plug

114. Hydraulic system pressure intake (on drive system pump)

115. Hydraulic system pressure intake (at suction fan pump)

116. Hydraulic system pressure intake (at accessory and

117. steering system pump)

Hopper lid suction sealing gasket

118. Document holder

119. Hopper lifting/lowering lever safety ﬂ ange

120. Suction inlet and broom lifting/lowering lever safety ﬂ ange

121. Driver’s seat forward/backward adjustment lever

122. Ashtray

123. High-pressure water gun sprinkler nozzle

124. Cigarette lighter

125. Can holder

126. Broom speed adjuster (***)

127. Hydraulic system oil level indicator

128.

(*) Optional for some countries.

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MACHINE NOMENCLATURE (Continues)

SERVICE MANUAL

GENERAL INFORMATION

ENGLISH

104

103

100

112

111

3101113

115

102

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GENERAL INFORMATION

MACHINE NOMENCLATURE (Continues)

105

118

106

114

128

107

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MACHINE NOMENCLATURE (Continues)

SERVICE MANUAL

GENERAL INFORMATION

ENGLISH

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GENERAL INFORMATION

MACHINE NOMENCLATURE (Continues)

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SERVICE MANUAL

SWEEPING SYSTEM

DESCRIPTION

The sweeping system consists of: A)

Right side broom

Left broom

Broom arms

The brooms (A) and (B) are supported by arms (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

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SERVICE MANUAL

SWEEPING SYSTEM

TROUBLESHOOTING

The brooms do not clean correctly

Possible causes:

The brooms are not adjusted correctly (adjust).

1. 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).

1. The hydraulic motors are faulty (replace).

2. The accessory system hydraulic pump does not pressurize the oil in the circuit (check the hydraulic system oil pressure).

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SERVICE MANUAL

ENGLISH

SWEEPING SYSTEM

SIDE BROOM POSITION CHECK AND ADJUSTMENT

NOTE

Brooms of various hardness are available. This procedure is applicable to all types of brooms.

Check

Check the side brooms for proper height and tilting, according to the following procedure:

1. Drive the machine on a level ground.

• While keeping the machine stationary, fully lower the side brooms and allow them to rotate for a few seconds.

• Stop and lift the side brooms, then move the machine.

• Check that the size and orientation of the prints left by the side brooms are as follows:

• The right side broom must touch the ground along a circle arc (A) ranging from “11 o’clock” position to “4 o’clock” position.

• The left side broom must touch the ground along a circle arc (B) ranging from “8 o’clock” position to “1 o’clock” position.

•

Adjust the broom height when the prints are out of speciﬁ cation, according to the following procedure. Engage the parking brake with the lever (66).

2. 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 screws (E) and (F), then adjust the forward tilting angle (G).

6. When the adjustment is completed, tighten the screws (E) and (F). Perform step 1 again.

Broom side tilting angle adjustment

On both sides of the machine, loosen the screws (I) and (L), then adjust the side tilting angle (H).

8. When the adjustment is completed, tighten the screws (I) and (L). Perform step 1 again.

Broom side position adjustment

The purpose of this adjustment is to improve the side position of the brooms as to the suction inlet (12).

10. To perform the adjustment, loosen the nuts (J) and operate on the screw (K), thus changing the side position of the brooms.

11. When the side brooms are too worn out, the adjustment is not possible; replace the brooms according to the instructions in the

12. relevant paragraph.

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SERVICE MANUAL

SWEEPING SYSTEM

SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues)

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SERVICE MANUAL

BROOM REPLACEMENT

NOTE

Brooms of various hardness are available. This procedure is applicable to all types of brooms.

CAUTION!

It is advisable to use protective gloves when cleaning the side brooms because there can be sharp debris between the bristles.

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 ﬂ ange (E).

Install the ﬂ ange (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 height of the new broom according to the procedure shown in the previous paragraph.

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SWEEPING SYSTEM

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SERVICE MANUAL

SWEEPING SYSTEM

BROOM SPEED ADJUSTMENT

Speed measurement

Engage the parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it. Connect a speed measurement indicator with a portable tachometer to the broom (10) or (11).

Start the machine and run 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 speed, loosen the locknut (A) and turn the screw (B), then tighten the locknut (A).

Perform step 4 again.

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ENGLISH

DUST AND DEBRIS COLLECTION SYSTEM

DESCRIPTION

The dust and debris collection system consists of:

Suction fan

Dust and debris suction ﬁ lter

Hopper

Suction hose

Suction inlet

Skirt

Gasket between suction inlet and hopper

Hopper lid

Hopper suction hole

Open lid support rod

Lifted hopper locking pins

Lifted hopper locking pins housing

Lifted hopper locking pins holes

Air breather ﬁ lter

Hopper lid suction sealing gasket

The suction fan (A), activated by an hydraulic motor, creates vacuum inside the hopper (C). The vacuum determines the suction capacity of the suction inlet (E) through the suction hose (D).

The hopper (C) is made of steel. It is fastened with two pins to a mechanic/hydraulic lifting system (O) (for hopper lifting) and to a dumping system (P) (for hopper tilting). The lid (H), which can be opened with an hydraulic 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 ﬁ lters having the following functions:

The suction ﬁ lter (B) retains dust and debris during fan suction phase, and makes them settle in the hopper;

–

The breather ﬁ lter (N) retains dust and debris escaped from the suction ﬁ lter, and does not allow them to be discharged

–

externally.

Both ﬁ lters can be easily removed and cleaned.

To perform checks and maintenance procedure safely with the hopper lifted and the lid opened, perform the following procedures:

Turn the rod (J) to lock the lid (H) in open position.

–

Remove the pins (K) from the housings (L) and place them into the holes (M) to lock the hopper (C) in lifted and dumped

–

position.

The suction inlet is made of sheet steel. It is equipped with three wheels, which allow it to follow the pattern of the surface to be cleaned. On its front side there is a skirt (F) that must be lifted to collect bulky debris.

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

DESCRIPTION (Continues)

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DUST AND DEBRIS COLLECTION SYSTEM

TROUBLESHOOTING

The suction fan turns but it is not efﬁ cient

Possible causes:

The ﬁ lters are clogged (clean).

1. The suction hose is clogged (clean).

2. The suction hose is cut/torn (replace).

3. The gasket between the suction inlet and the hopper is broken or misadjusted (replace or adjust).

4. The hopper lid gasket is broken (replace).

5. There is no pressure at the suction fan motor drive pump (adjust the pump pressure).

The suction fan does not turn

Possible causes:

The motor is faulty (replace).

1. The control valve assembly is stuck (repair).

2. The pump is faulty (replace).

The suction inlet does not collect debris efﬁ ciently

Possible causes:

The suction inlet position is incorrect (check the suction inlet and skirt height and efﬁ ciency).

The skirt opening force is not sufﬁ cient

Possible causes:

The skirt opening pressure is incorrect (adjust).

The hopper does not lift/lower

Possible causes:

The control valve assembly is stuck (repair).

1. The cylinder gaskets are worn (repair the cylinder).

The rear lid does not open/close

Possible causes:

There is no voltage in the actuator (repair the electrical system).

1. The actuator is faulty (repair/adjust the actuator cams).

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK

WARNING!

Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun.

Preliminary operations

Empty the hopper (3), drive the machine to a cleaning/washing appointed area, then engage the parking brake with the lever

1. (66). Lift and dump the hopper (3), according to the procedure shown in the User Manual.

2. Install the lid support rod (27).

Hopper cleaning

Clean the hopper (H) with pressurised water from a hydrocleaner (G).

4. Carefully check the suction sealing gasket (U) for integrity, and replace it if necessary.

Suction hose cleaning

Thoroughly clean the suction hose (R) inside, up to the suction inlet, with pressurised water.

6. Carefully check the suction sealing gasket (V) for integrity, and replace it if necessary.

Suction ﬁ lter cleaning

Inside the hopper, remove the suction ﬁ lter fastener (A).

8. Remove the suction ﬁ lter (B).

9. Wash the deﬂ ector (C) and the fan (D) with pressurised water; check that all fan sectors (T) are clean.

10. Clean the suction ﬁ lter (F) with pressurised water from a hydrocleaner (E).

11. Install the suction ﬁ lter (B) and secure it with the fastener (A).

12. Remove the lid support rod (27) and lower the hopper (3) according to the procedure shown in the User Manual.

13. Turn the ignition key (76) to OFF position and remove it.

14.

Breather ﬁ lter cleaning

With a ladder and the help of an assistant, disengage the fasteners (I) of the breather ﬁ lter hood (J).

15. Open the hood (K) and install the safety pin (L).

16. Remove the mounting screws (M), then remove the breather ﬁ lter (N).

17. Clean the breather ﬁ lter (P) with pressurised water from a hydrocleaner (O).

18. Install the breather ﬁ lter and its hood performing steps from 15 to 17 in reverse order.

19.

33015500(3)2008-02 RS 501

SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)

ENGLISH

DCB

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DUST AND DEBRIS COLLECTION SYSTEM

HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)

NMPO

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DUST AND DEBRIS COLLECTION SYSTEM

SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK

Preliminary operations

Engage the parking brake with the lever (66).

1. Lift the suction inlet (12), according to the procedure shown in the User Manual.

2. Turn the ignition key (76) to OFF position and remove it.

Suction inlet wheel check

Check that the three wheels (A) of the suction inlet are in good conditions and turn freely (they must not be bent/misshapen

4. because of bumps or excessive pressure, etc.). Check also that the rubber thickness (B) is not lower than some millimeters. If necessary replace the wheels (A) (see the procedure in relevant paragraph).

Sliding panel check

Check that the main sliding panel (C) and the front (D) and (E) and rear (H) sliding panels are in good conditions and that their

5. thickness (F) is not lower than 5 mm, otherwise replace them (see the procedure in the relevant paragraph). It is important to replace the sliding panels (C), (D), (E), and (H) when they are not completely worn, to avoid damaging the relevant mounting screws and making them difﬁ cult to remove. Replace the sliding panels (C), (D), (E), and (H) as a unit, to avoid steps in the union areas (G), caused by different levels of wear.

Suction inlet skirt and wheel adjustment check

Check that the skirt (I) is integral and that it does not have excessive tears (J) or lacerations (K), which can affect the suction

6. 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.

7. Turn the ignition key (76) to OFF position and remove it.

8. Check that the distance (L) of the skirt from the ground is not bigger than 1 cm. Greater distances can affect the suction inlet

9. operation. If necessary replace the skirt (K) (see the procedure in the relevant paragraph). Also check that, when the three wheels (A) contact the ground, the sliding panels (C), (D), (E), and (H) do not touch the

10. ground, otherwise the wheels (A) must be replaced to avoid an excessive wear of the sliding panels (for wheel replacement procedure, see the relevant paragraph). Start the machine according to the procedure shown in the User Manual, then press the switch (69) and check that the skirt

11. (I) lifts freely. Check that it lifts also when a force of some kg is applied (simulating to move bottles or other heavy objects that must then be collected). If necessary, adjust the opening force of the skirt (I) according to the following procedure:

Turn off the machine.

•

Remove the screws and the right panel (22) in the cab.

•

Loosen the control valve locknut (N) and turn the screw (O) as necessary, reminding that:

•

The opening force decreases by loosening the screw;

–

The opening force increases by tightening the screw.

– When the adjustment is completed, tighten the locknut (N).

•

Install the right panel (22) in the cab and tighten the screws.

•

Reset

Assemble the components in the reverse order of disassembly.

12.

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK (Continues)

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DUST AND DEBRIS COLLECTION SYSTEM

SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY

NOTE

To remove the rear wheel (C), the machine must be lifted with an appropriate hoisting system. Otherwise, remove the suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following disassembling procedures.

Front wheels (A) and (B) removal/installation

Engage the parking brake with the lever (66).

1. Lift the suction inlet (12), according to the procedure shown in the User Manual.

Turn the ignition key (76) to OFF position and remove it.

On both sides of the machine, loosen the 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 hoisting system is not available, remove the suction inlet assembly (D) (see the procedure in the relevant paragraph).

Remove the screws (E), (F) and (G), then remove the wheels (A), (B) and (C).

Install the new wheels (A), (B) and (C) and fasten them with the screws (E), (F) and (G).

10.

Perform step 1 again.

11.

If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY

NOTE

To remove the suction inlet sliding panels, the machine must be lifted with an appropriate hoisting system. Otherwise, remove the suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following disassembling procedures.

Place the machine on the appropriate hoisting system (if present) and lift it.

1. If the hoisting system 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 replaced to avoid an excessive wear of the sliding panels (for wheel replacement procedure, see the relevant paragraph).

Perform step 1 again.

If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).

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ENGLISH

DUST AND DEBRIS COLLECTION SYSTEM

SUCTION INLET DISASSEMBLY/ASSEMBLY

Disassembly

Remove the side brooms (see the procedure in the relevant paragraph). Lower the suction inlet (12), according to the procedure shown in the User Manual.

2. Engage the parking brake with the lever (66).

3. Turn the ignition key (76) to OFF position and remove it.

4. Disconnect the hydraulic system hoses (A) and (B) from the suction inlet (C) and plug them.

5. Disconnect the dust control system water hose (D).

6. Remove the nuts (E) and pins (F).

7. Move the suction inlet (C) forward, and loosen the suction hose clamp (G).

8. Disconnect the suction hose (H) from the suction inlet.

9. Remove the suction inlet (C).

10.

Assembly

Assemble the components in the reverse order of disassembly.

11. If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

SKIRT REPLACEMENT

Lower the suction inlet (12), according to the procedure shown in the User Manual.

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.

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DUST AND DEBRIS COLLECTION SYSTEM

HOPPER POSITION ADJUSTMENT

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

3. Lift the hopper (3), according to the procedure shown in the User Manual.

4. Turn the ignition key (76) to OFF position and remove it.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Loosen the locknuts (A).

7. Insert a lever into the holes (C), then turn the rods (B) as necessary.

8. Remove the locking pins (28) and place them into the holes (29).

9. Lower the hopper (3), according to the procedure shown in the User Manual, and check that the proﬁ les (D) match the frame

10. proﬁ les (E). If necessary, perform steps 4, 5, 6, 8, 9 and 10 again.

11. Then perform steps 3, 4, 5 and tighten the locknuts (A).

12. Lower the hopper (3), according to the procedure shown in the User Manual, and check that the hopper suction hole (F) match

13. the suction hose gasket (G). If necessary, adjust the position of the suction hose (H) according to the procedure shown in the following steps. Perform steps 4, 5 and 6 again.

14. Loosen the left and right side screws (I) (J) and (L), then adjust the position of the suction hose (H). Tighten the left and right

15. side screws (I) (J) and (L). Lower the hopper (3), according to the procedure shown in the User Manual, and check that the hopper suction hole (F) match

16. the suction hose gasket (G). Close the right and left lids (20) and (18) by engaging the fasteners (21) and (19) with the supplied key.

17.

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

HOPPER POSITION ADJUSTMENT (Continues)

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DUST AND DEBRIS COLLECTION SYSTEM

HOPPER LID CLOSING ACTUATOR ADJUSTMENT

Preliminary operations

Empty the hopper (3), according to the procedure shown in the User Manual. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right lid (20) by releasing the fasteners (21) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Remove the screws (A), then remove the cover (B) and the gasket (C) of the actuator (R), under the rear side of the hopper.

Lid safety hook closing

According to the procedure shown in the User Manual, turn the safety hook (D) of the lid (E) to closing position (as shown

8. in the ﬁ gure); 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 ﬁ gure), loosen the security dowel (I) of the

9. cam (J), and turn the cam until the corner (K) causes the microswitch (L) to activate and the warning light to turn off.

Lid safety hook opening end-of-stroke adjustment

According to the procedure shown in the User Manual, turn the safety hook (D) of the lid (E) to the opening end-of-stroke; in

10. this condition, loosen the security dowel of the cam (N), and then turn the cam until the microswitch (O) activates.

NOTE

To maximize cam adjustment consider the following:

The cam turns in the direction shown by the arrow (P) when the hook (D) opens;

–

The cam turns in the direction shown by the arrow (Q) when the hook (D) closes.

–

To check the cam proper adjustment, open and close the hook (D) several times.

11.

Reset

12.

Perform steps 3 to 7 in the reverse order.

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

HOPPER LID CLOSING ACTUATOR ADJUSTMENT (Continues)

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DUST AND DEBRIS COLLECTION SYSTEM

MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY

Disassembly

Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it.

2. With a ladder and the help of an assistant, disengage the fasteners (A) of the breather ﬁ lter hood (B).

3. Open the hood (C) and install the safety pin (D).

4. Remove the mounting screws (E), then remove the breather ﬁ lter (F).

5. Disconnect the hoses joints (G) and (H) from the suction fan motor (I).

6. Remove the mounting nuts (J) of the ﬂ ange (M).

7. With an appropriate hoisting system, remove the suction fan motor assembly (K) by removing the silicone along the perimeter

8. (L) of the ﬂ ange (M), then sling the assembly (K) by placing a rope around the motor (I) and the ﬁ ttings (N). At the workbench, remove the screw (O) and the fan (P).

9. Remove the nuts (Q) from the screws (R).

10. Remove the motor (I) from the ﬂ ange (M).

11.

Assembly

12.

Assemble the components in the reverse order of disassembly and note the following:

•

Remove the silicone along the perimeter (L) of the ﬂ ange (M) and from the ﬂ ange housing on the hopper.

•

Apply new silicone along the perimeter (L) of the ﬂ ange (M).

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues)

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DUST AND DEBRIS COLLECTION SYSTEM

SUCTION HOSE DISASSEMBLY/ASSEMBLY

Preliminary operations

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).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

5. 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).

7. Loosen the left and right side mounting screws (D) of the suction hose upper end (E).

8. Remove the suction hose (F) by pulling it upwards.

Assembly

Assemble the components in the reverse order of disassembly and note the following:

10.

For a easier installation of the suction hose (B) into the suction inlet (C), apply a thin coat of grease on the sliding parts.

•

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM

33016312(0)2007-04 RS 501 UK

DUST CONTROL SYSTEM

DESCRIPTION

The dust control system consists of: A)

Right water tank

Left water tank Tank ﬁ ller plugs

Broom nozzles

Suction inlet nozzles

Water ﬁ lter

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

SERVICE MANUAL

DUST CONTROL SYSTEM

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S301489

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SERVICE MANUAL

DUST CONTROL SYSTEM

TROUBLESHOOTING

No water from the nozzles

Possible causes:

The water ﬁ lter is clogged (clean/replace).

1. The nozzles are clogged (clean).

No water to the nozzles

Possible causes:

The water pump relay is burned (replace).

1. The pump does not work (repair/replace).

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SERVICE MANUAL

ENGLISH

DUST CONTROL SYSTEM

NOZZLE AND FILTER CLEANING

WARNING!

Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun.

Preliminary operations

Engage the parking brake with the lever (66).

1. Turn the ignition key (76) to OFF position and remove it.

Cleaning of nozzles and ﬁ lters on brooms

Unscrew the ring nuts (A).

3. Clean the nozzles (B) and ﬁ lters (C) with compressed air. Remove calcium deposits. If necessary, replace the ﬁ lters (C).

4. Install the ﬁ lters 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).

6. Clean the nozzles (F) and screws (E) with compressed air. Remove calcium deposits.

7. Assemble the components in the reverse order of disassembly.

Cleaning of nozzle and ﬁ lter in the rear suction pipe

Remove the screw (G), the nozzle (H) and the ﬁ lter (I).

9. Clean the nozzle (H) and ﬁ lter (I) with compressed air. Remove calcium deposits. If necessary, replace the ﬁ lter (I).

10. Assemble the components in the reverse order of disassembly.

11.

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SERVICE MANUAL

DUST CONTROL SYSTEM

NOZZLE AND FILTER CLEANING (Continues)

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SERVICE MANUAL

DUST CONTROL SYSTEM

WATER FILTER CLEANING

WARNING!

Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun.

NOTE

When the ﬁ lter is removed, the water inside the tanks comes out up to the ﬁ lter 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 ﬁ lter cover (A) together with the ﬁ lter (B). Separate the ﬁ lter (B) from the cover (A), then wash and clean it. If necessary, replace the ﬁ lter (B).

4. Install the ﬁ lter (B) and the cover (A).

If necessary, ﬁ ll the water tanks.

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SERVICE MANUAL

DUST CONTROL SYSTEM

WATER TANK EMPTYING

When necessary, empty 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).

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ENGLISH

STEERING SYSTEM

DESCRIPTION

The steering wheel activates the steering gearbox, which controls an hydraulic cylinder that operates on the rear wheels assembled on a steering axle.

The steering system consists of: A)

Oil pump

Priority valve

Steering gearbox

Rear wheel control hydraulic cylinder

Hydraulic system oil tank

Hydraulic system hoses

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SERVICE MANUAL

STEERING SYSTEM

TROUBLESHOOTING

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).

1. The priority valve is faulty (replace).

2. The rear wheel control hydraulic cylinder is faulty (replace).

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SERVICE MANUAL

ENGLISH

STEERING SYSTEM

REAR AXLE TOE-IN ADJUSTMENT

Drive the machine on a solid and level ground and keep the rear wheels (A) in a straightforward position, then engage the

1. parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it. Prepare two metal plates (B) to be used as reference lines. The plates must be a little longer 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 ﬁ gure. 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 of 4 mm between the two distances is admitted. If necessary, adjust the distances by loosening the nuts (D) and turning the tie rods (C). Then tighten the nuts (D).

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SERVICE MANUAL

STEERING SYSTEM

REAR AXLE TOE-IN ADJUSTMENT (Continues)

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BRAKE SYSTEM

DESCRIPTION

The machine is equipped with an hydraulic brake system controlled by pedal, which actuates on the drum brakes of the front wheels.

The brake system consists of: A)

Brake pedal

Brake ﬂ uid 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

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SERVICE MANUAL

BRAKE SYSTEM

TROUBLESHOOTING

The machine brake system is not efﬁ cient

Possible causes:

The brake ﬂ uid is insufﬁ cient (check the ﬂ uid level).

1. The brake ﬂ uid pump is faulty (overhaul).

2. There is air in the system (bleed).

3. The drum brake cylinder is faulty (replace).

4. The braking masses are worn or greasy (replace).

The parking brake is not efﬁ cient

Possible causes:

The brake is misadjusted (adjust).

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SERVICE MANUAL

ENGLISH

BRAKE SYSTEM

BRAKE FLUID LEVEL CHECK

Engage the parking brake with the lever (66).

1. Turn the ignition key (76) to OFF position and remove it.

2. Open the right lid (20).

3. Check that the ﬂ uid level in the tank (A) is approximately at 1 cm from the ﬁ ller neck.If necessary, top up using the same type of ﬂ uid that is in the line.Type of ﬂ uid used: DOT4.

Close the right lid (20).

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SERVICE MANUAL

BRAKE SYSTEM

PARKING BRAKE CHECK AND ADJUSTMENT

Check

Engage the parking brake lever (66) and check for proper operation. Check also that the brake operates in the same way on both the front wheels. If necessary, adjust the parking brake according to the following procedure.

Adjustment

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

2. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

3. Lift the hopper (3), according to the procedure shown in the User Manual.

4. Turn the ignition key (76) to OFF position and remove it.

5. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

6. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

7. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

8. 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

10. on the type of adjustment (same adjustment for both wheels, or adjustment of one wheel only if braking is unbalanced):

To adjust both cables (I) in the same way: loosen the locknuts (D), move the bracket (B) as necessary along the tie rod (C),

•

then tighten the locknuts (D); or loosen the locknuts (G) and (H), give the tie rods (E) and (F) the same number of turns, then tighten the locknuts (G) and (H). To adjust just one of the cables (I): loosen the locknuts (G) or (H), turn the tie rods (E) or (F), then tighten the locknuts (G)

•

or (H).

11.

Perform steps 4, 5, 6, 7 and 9 in the reverse order.

12.

If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

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ENGLISH

BRAKE SYSTEM

PARKING BRAKE CONTROL CABLE REPLACEMENT

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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), unscrew the locknuts (C) and (D), disconnect the control cable (E) or (F) and

9. recover the relevant spring (G). Remove the front wheel (see the procedure in the relevant paragraph).

10. Place safety stands under the machine side sill.

11. Remove the screw (H) and the screws (I), then remove the washer (J).

12. Remove the drum (K).

13. Remove the three springs (L).

14. Remove the shoe retaining springs (M).

15. Remove the shoes (N) by disengaging the parking brake control cable (O) from the lever (P).

16. Perform steps 3 to 6 and 8 to 16 in the reverse order.

17. Adjust the parking brake (see the procedure in the relevant paragraph).

18. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

19.

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SERVICE MANUAL

BRAKE SYSTEM

PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues)

33015500(3)2008-02 RS 501

S300885

BRAKE SYSTEM CHECK

Check the brake ﬂ uid level (see the procedure in the relevant paragraph).

1. Press the brake pedal (57) several times, and check that brakes operate properly.

2. Check that there are no leaks from the brake system.

3. If necessary, check/replace the brakes (see the procedure in relevant paragraph).

4. If necessary, bleed the brake system (see the procedure in the relevant paragraph).

SERVICE MANUAL

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BRAKE SYSTEM

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SERVICE MANUAL

BRAKE SYSTEM

BRAKING MASSES REPLACEMENT

Remove the front wheel (see the procedure in the relevant paragraph).

1. Place safety stands under the machine side sill, on the side where the wheel has been removed.

2. Remove the screw (A) and the screws (B), then remove the washer (C).

3. Remove the drum (D).

4. Remove the three springs (E).

5. Remove the shoe retaining springs (F).

6. Remove the shoes (G) together with the braking masses, by disengaging the parking brake control cable (H) from the lever (I).

7. Perform steps 1 to 7 in the reverse order.

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BRAKE SYSTEM

BRAKE SYSTEM BLEEDING

WARNING!

Brake system bleeding must be always performed with the system opened. It must also be performed on both front wheels.

Check the brake ﬂ uid level (see the procedure in the relevant paragraph).

Remove one of the front wheels (see the procedure in the relevant paragraph).

Place safety stands under the machine 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 ﬂ uid.

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 valve (A) and release the brake pedal (57).

Perform steps 2 to 4 in the reverse order.

Bleed the brake system also on the other front wheel, by performing steps from 2 to 6 again.

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BRAKE SYSTEM

SERVICE MANUAL

33016312(0)2007-04 RS 501 UK

SERVICE MANUAL

DRIVE SYSTEM

DESCRIPTION

The drive pedal controls two independent drive system hydraulic motors applied to the front wheels. Front and rear wheels are pneumatic.

The drive system consists of: A)

Drive pedal

Right drive system motor

Left drive system motor

Drive system pump

Hydraulic system oil tank

Hoses

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DRIVE SYSTEM

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SERVICE MANUAL

DRIVE SYSTEM

TROUBLESHOOTING

The machine stability is reduced

Possible causes:

The tires are not correctly inﬂ ated (check tire pressure).

The rear axle is noisy

Possible causes:

The wheel bearings are worn (replace).

The machine power is reduced

Possible causes:

The drive system motors are worn (replace).

1. The drive pedal is faulty (replace).

2. 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).

1. There are oil leaks from the hydraulic system (repair).

2. The drive system pump is broken (replace).

3. The drive system motor is broken (replace).

The machine moves even if the drive pedal is released

Possible causes:

The drive pedal is misadjusted (adjust).

33015500(3)2008-02 RS 501

TIRE PRESSURE CHECK

Engage the parking brake with the lever (66).

1. Turn the ignition key (76) to OFF position and remove it.

2. The tire pressure should be as follows:

Front tires: 3.75 Bar

•

Rear tires: 3.75 Bar

•

SERVICE MANUAL

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DRIVE SYSTEM

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SERVICE MANUAL

DRIVE SYSTEM

REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR ADJUSTMENT

Check

Check that, when the machine moves in reverse, the relevant buzzer sounds. If necessary, adjust the relevant sensor according to the following procedure.

Adjustment

Engage the parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it.

Check that the surface (A) of the sensor (B) is ﬂ ush 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 play. If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed, tighten the nuts (G) and (H).

Perform step 1 again.

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SERVICE MANUAL

REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY

Disassembly

Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it.

2. Cut the cable clamp (A) under the right side of the cab.

3. Disconnect the reverse gear buzzer activation sensor connector (B).

4. Remove the four mounting screws (D) of the drive pedal (E).

5. Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).

6. Remove the sensor (C), the harness (G) and the connector.

Assembly

Assemble the components in the reverse order of disassembly.

8. Adjust the reverse gear buzzer activation sensor (see the procedure in the relevant paragraph).

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DRIVE SYSTEM

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SERVICE MANUAL

DRIVE SYSTEM

WHEEL REMOVAL/INSTALLATION

Preliminary operations

Turn the ignition key (76) to OFF position and remove it. Engage the parking brake with the lever (66).

2. Check that the machine cannot move with one wheel lifted (the parking brake operates only on the front wheels). If necessary

3. keep the machine stationary by placing wedges on the wheels contacting the ground. Remove the wheel according to the following procedure.

Rear wheel removal/installation

Place the jack (A) (not equipped) under the relevant housing (D) in the rear axle (B), as shown in the ﬁ gure.

5. Carefully activate the jack (A), and lift the wheel (C) until it is slightly detached from the ground.

6. Remove the mounting nuts, then remove the wheel (C).

7. Install the wheel (C) by performing steps from 5 to 7 in the reverse order.

8. 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 machine side sill, in front of the wheel (G), as shown in the ﬁ gure.

10.

Carefully activate the jack (E) (not equipped), and lift the wheel (G) until it is slightly detached from the ground.

11.

Remove the mounting nuts, then remove the wheel.

12.

Install the wheel by performing steps from 9 to 11 in the reverse order. Wheel mounting nut tightening torque: 400 N·m

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ENGLISH

DRIVE SYSTEM

DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY

Remove the suction inlet (see the procedure in the relevant paragraph).

1. Remove the front wheel (see the procedure in the relevant paragraph). Place safety stands under the machine side sill, on the

2. side where the wheel has been removed.

Disconnect the brake system pipes (A) from the brake assembly (B) and plug them immediately.

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 ﬁ ve 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 (see the procedure in the relevant paragraph).

Check the brake system (see the procedure in the relevant paragraph).

Adjust the parking brake (see the procedure in the relevant paragraph).

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SERVICE MANUAL

DRIVE SYSTEM

DRIVE PEDAL CHECK AND ADJUSTMENT

Preliminary operations

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

Check

Drive the machine on a level and smooth ground, and, with the engine on, check that the machine does not move forward or

2. backward when the drive pedal (56) is not pressed. If the machine moves, even though slightly, check the drive pedal, according to the following procedure.

Drive pedal check

Engage the parking brake with the lever (66).

3. Turn the ignition key (76) to OFF position.

4. Check that the drive pedal (56) turns freely on its shaft and that it does not bind/slow down, which may prevent the pedal from

5. resuming the neutral position. If necessary, remove the possible cause for binding/slowing down, then repeat step 1. If the problem persists, adjust the drive system pump as shown below.

Drive system pump adjustment

Disengage the parking brake with the lever (66).

6. Stop the left front wheel with two wedges (A).

7. Remove the right front wheel according to the procedure shown in the relevant paragraph.

8. Place safety stands under the machine side sill, on the side where the wheel has been removed.

9. Lift the hopper (3) for 20 cm, according to the procedure shown in the User Manual.

10. Turn the ignition key (76) to OFF position and remove it.

11. Open the right lid (20) by releasing the fasteners (21) with the supplied key.

12. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

13. Remove the screw (44) and open the right tank (43).

14.

WARNING!

Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

Turn on the diesel engine with care.

15.

WARNING!

When the diesel engine is running, the wheel hub (B) can be rotating.

Check that the machine is in the following conditions:

16.

Diesel engine is running

•

Drive pedal (56) is not pressed

•

Brakes and parking brake are not activated

• In these conditions, operating on the drive system pump (C), loosen the locknut (D) then turn the threaded dowel (E) clockwise or counter-clockwise, until the hub (B) stops. Tighten the locknut (D). Engage the parking brake with the lever (66).

17. Turn the ignition key (76) to OFF position.

18. Perform steps 6 to 12 in the reverse order.

19. Perform step 1 again.

20. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

21.

33015500(3)2008-02 RS 501

DRIVE PEDAL CHECK AND ADJUSTMENT (Continues)

SERVICE MANUAL

ENGLISH

DRIVE SYSTEM

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DRIVE SYSTEM

SERVICE MANUAL

33016312(0)2007-04 RS 501 UK

SERVICE MANUAL

ENGLISH

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: A)

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).

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SERVICE MANUAL

LDW 1603/B2 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.

33015500(3)2008-02 RS 501

SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE OIL LEVEL CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 Diesel Engine Manual.

9. If necessary, add oil according to the procedure shown in the Diesel Engine Manual.

10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

11. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

12.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE OIL CHANGE

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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.

Change oil according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE OIL FILTER CHANGE

NOTE

This procedure must be performed when the engine oil has been drained.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. 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 oil ﬁ lter according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE COOLANT LEVEL CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. 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 procedure shown

7. in the Diesel Engine Manual. If necessary, unscrew the plug (B) and top up. Coolant components:

•

50% of AGIP antifreeze 50% of water

• After top up, tighten the plug (B).

Perform steps 3 to 6 in the reverse order.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE AIR FILTER CLEANING

WARNING!

Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning operations using compressed air gun.

Preliminary operations

Engage the parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it.

Open the left lid (18) by releasing the fasteners (19) with the supplied key.

Pre-ﬁ lter cleaning

Remove the screw (A), then remove the pre-ﬁ lter (B).

Clean and wash the pre-ﬁ lter, then install it.

Filter cleaning

Remove the screw (C), then remove the cover (D).

Remove the outer ﬁ lter (E) and the inner ﬁ lter (F).

Clean the ﬁ lters (E) and (F) carefully with compressed air (maximum 6 Bar) and replace them, if necessary.

Install the ﬁ lters (E) and (F).

10.

Install the cover (D) and the screw (C).

11.

Close the left lid (18) by engaging the fasteners (19) with the supplied key.

ENGLISH

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SERVICE MANUAL

LDW 1603/B2 ENGINE

FUEL FILTER REPLACEMENT

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 ﬁ lter according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

33015500(3)2008-02 RS 501

SERVICE MANUAL

ENGLISH

LDW 1603/B2 ENGINE

FUEL FITTING AND SCREW CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 ﬁ lter (A) and on the diesel engine, check the sealing of fuel system ﬁ ttings (B). Repair if necessary.

9. Operating on the fuel tank (C), check the sealing of fuel system ﬁ ttings (D). Repair if necessary.

10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

11. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

12.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ALTERNATOR BELT TENSION CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right lid (20) by releasing the fasteners (21) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 alternator belt tension according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

33015500(3)2008-02 RS 501

SERVICE MANUAL

LDW 1603/B2 ENGINE

ALTERNATOR BELT REPLACEMENT

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right lid (20) by releasing the fasteners (21) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 alternator belt tension according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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RS 501 33015500(3)2008-02

ENGLISH

SERVICE MANUAL

LDW 1603/B2 ENGINE

RADIATOR FIN CLEANING CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 water approximately.

Check the radiator ﬁ n cleaning according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

33015500(3)2008-02 RS 501

SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE COOLANT LINE SLEEVE CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 approximately.

Check the coolant line sleeves according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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SERVICE MANUAL

LDW 1603/B2 ENGINE

ENGINE COOLANT CHANGE

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 engine coolant according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

33015500(3)2008-02 RS 501

SERVICE MANUAL

LDW 1603/B2 ENGINE

INJECTOR CALIBRATION AND CLEANING

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 the injectors according to the procedure shown in the Diesel Engine Manual.

9. Perform steps 3 to 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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RS 501 33015500(3)2008-02

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SERVICE MANUAL

LDW 1603/B2 ENGINE

33016312(0)2007-04 RS 501 UK

CLIMATE CONTROL SYSTEM

DESCRIPTION

The climate control system consists of: A)

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 ﬁ lter

SERVICE MANUAL

ENGLISH

CLIMATE CONTROL SYSTEM

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SERVICE MANUAL

CLIMATE CONTROL SYSTEM

TROUBLESHOOTING

No fresh air from the climate control system

Possible causes:

The compressor does not turn because the drive belt is loosen/broken (tension/replace the belt).

1. There are gas leaks from the system (repair the leak and integrate the gas).

2. The expansion valve is faulty (replace).

No hot air from the climate control system

Possible causes:

The hot water hoses are broken (replace).

1. There are water leaks from the heater (replace).

33015500(3)2008-02 RS 501

SERVICE MANUAL

CLIMATE CONTROL SYSTEM

COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine)

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the right lid (20) by releasing the fasteners (21) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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 position (C) with a force of 10 kg and check that the belt does not bend for more than 1

•

cm. If necessary, loosen the nuts (D) and (E), and adjust the tension of the belt (A). Tighten the nuts (D) and (E). Perform steps 3, 4, 5, 6 and 8 in the reverse order.

10. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

11.

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SERVICE MANUAL

CLIMATE CONTROL SYSTEM

COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine)

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Lift the hopper (3), according to the procedure shown in the User Manual.

3. Turn the ignition key (76) to OFF position and remove it.

4. Open the left lid (18) by releasing the fasteners (19) with the supplied key.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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).

9. Remove the belt (B) from the pulleys.

10. Place the new belt (B) on the pulleys.

11. Adjust the compressor belt tension according to the procedure shown in the previous paragraph.

12. Perform steps 3, 4, 5, 6 and 8 in the reverse order.

13. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

14.

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SERVICE MANUAL

AIR FILTER REPLACEMENT

Engage the parking brake with the lever (66).

1. Turn the ignition key (76) to OFF position and remove it.

2. Remove the screws (A) and the panel (B) in the cab.

3. Unscrew the knobs (F) and remove the panel (C).

4. Remove the cab air ﬁ lter (D).

5. Install the new ﬁ lter (D) with the arrows (E) pointing in the direction of the air ﬂ ow (upwards).

6. Perform steps 3 and 4 in the reverse order.

ENGLISH

CLIMATE CONTROL SYSTEM

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SERVICE MANUAL

CLIMATE CONTROL SYSTEM

33016312(0)2007-04 RS 501 UK

SERVICE MANUAL

OTHER SYSTEMS

NUT AND SCREW TIGHTENING AND LEAKAGE CHECK

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.

1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

2. Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.

3. Lift the hopper (3), according to the procedure shown in the User Manual.

4. Turn the ignition key (76) to OFF position and remove it.

5. Remove the locking pins (28) from the housings (29) and place them into the holes (30).

6. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.

7. 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).

9. Inspect the machine accessible parts and check for:

10.

Tightening of mounting screws and nuts;

•

Correct position of the fasteners;

•

Visible faults in the components;

•

Leaks of ﬂ uids (oil, etc.).

• Perform steps 3, 4, 5, 6 and 8 in the reverse order.

11. If necessary, ﬁ ll the dust control system water tanks according to the procedure shown in the User Manual.

12.

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RS 501 33015500(3)2008-02

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SERVICE MANUAL

OTHER SYSTEMS

LUBRICATION

Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).

1. Turn the ignition key (76) to OFF position and remove it.

2. Lubricate the rear axle knuckles with the grease nipples (A). If necessary, steer the rear wheels to reach the grease nipples

3. 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.

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SERVICE MANUAL

ENGLISH

OTHER SYSTEMS

CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE PEDAL IS PRESSED

Check

Check that it is not possible to start the machine with the ignition key (76) when the drive pedal (56) is pressed. If necessary, adjust the relevant sensor according to the following procedure.

Adjustment

Engage the parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it.

Perform step 1 again.

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SERVICE MANUAL

OTHER SYSTEMS

DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE PEDAL IS PRESSED

Disassembly

Engage the parking brake with the lever (66).

Turn the ignition key (76) to OFF position and remove it.

Cut the cable clamp (A) under 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 inhibition (see the procedure in the relevant paragraph).

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Nilfisk RS 501 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual