Nilfisk RS 501 User Manual 2
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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SERVICE MANUAL
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
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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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SERVICE MANUAL
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
2
/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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SERVICE MANUAL
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.
12
33015500(3)2008-02 RS 501
MACHINE NOMENCLATURE (Continues)
1
14
SERVICE MANUAL
GENERAL INFORMATION
ENGLISH
18
99
104
12
103
45
10
100
112
19
25
111
7
8
2
11
3101113
6
20
13
115
17
102
26
9
97
15
24
21
98
8
4
9
RS 501 33015500(3)2008-02
16
110
S301479
13
ENGLISH
SERVICE MANUAL
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
32
26
5
105
48
40
28
37
46
27
31
118
47
36
106
29
38
39
30
114
128
33
107
51
14
41
49
42
33015500(3)2008-02 RS 501
44
50
35
43
S301617
MACHINE NOMENCLATURE (Continues)
SERVICE MANUAL
GENERAL INFORMATION
ENGLISH
64
22
108
65
63
59
69
119
121
61
120
60
123
109
58
62
66
68
67
57
54
55
53
52
116
117
127
126
34
122
56
125
124
23
S301481
RS 501 33015500(3)2008-02
15
ENGLISH
SERVICE MANUAL
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
70
80
78
1
79
81
95
94
93
92
91
77 71
73 74
82
72
83 84
75
96
76
85
86
87
88
89
16
90
S301407
33015500(3)2008-02 RS 501
SERVICE MANUAL
SWEEPING SYSTEM
SWEEPING SYSTEM
DESCRIPTION
The sweeping system consists of:
A)
Right side broom
B)
Left broom
C)
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
C
ENGLISH
A
C
B
S300857
RS 501 33015500(3)2008-02
17
ENGLISH
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).
2.
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).
3.
18
33015500(3)2008-02 RS 501
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.
3.
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:
4.
To lower the broom, the nut (C) must be unscrewed;
•
To lift the broom, the nut (C) must be screwed.
•
Perform step 1 again.
5.
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.
7.
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.
9.
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.
RS 501 33015500(3)2008-02
19
ENGLISH
SERVICE MANUAL
SWEEPING SYSTEM
SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues)
20
S301482
33015500(3)2008-02 RS 501
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.
1.
Lift the brooms and engage the parking brake with the lever (66).
2.
Turn the ignition key (76) to OFF position and remove it.
3.
Remove the centre screw (A), then remove the broom (B) to be replaced. Recover the key.
4.
Remove the screws (D), then remove the fl ange (E).
5.
Install the fl ange (E) and secure it on the new broom with the screws (D).
6.
Install the new broom (B) with the key, then tighten the centre screw (A).
7.
Adjust the height of the new broom according to the procedure shown in the previous paragraph.
ENGLISH
SWEEPING SYSTEM
B
A
D
D
B
B
E
S300859
RS 501 33015500(3)2008-02
21
ENGLISH
SERVICE MANUAL
SWEEPING SYSTEM
BROOM SPEED ADJUSTMENT
Speed measurement
1.
Engage the parking brake with the lever (66).
2.
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).
3.
4.
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
5.
Remove the screws and the right panel (22) in the cab.
6.
To change the broom speed, loosen the locknut (A) and turn the screw (B), then tighten the locknut (A).
7.
Perform step 4 again.
22
B
A
S301510
33015500(3)2008-02 RS 501
SERVICE MANUAL
ENGLISH
DUST AND DEBRIS COLLECTION SYSTEM
DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION
The dust and debris collection system consists of:
Suction fan
A)
Dust and debris suction fi lter
B)
Hopper
C)
Suction hose
D)
Suction inlet
E)
Skirt
F)
Gasket between suction inlet and hopper
G)
Hopper lid
H)
Hopper suction hole
I)
Open lid support rod
J)
Lifted hopper locking pins
K)
Lifted hopper locking pins housing
L)
Lifted hopper locking pins holes
M)
Air breather fi lter
N)
Hopper lid suction sealing gasket
Q)
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.
RS 501 33015500(3)2008-02
23
ENGLISH
SERVICE MANUAL
DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION (Continues)
G
A
N
D
E
B
C
I
F
H
P
K
J
O
K
K
Q
M
L
S301483
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33015500(3)2008-02 RS 501
SERVICE MANUAL
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).
6.
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).
3.
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).
1.
The skirt opening force is not suffi cient
Possible causes:
The skirt opening pressure is incorrect (adjust).
1.
The hopper does not lift/lower
Possible causes:
The control valve assembly is stuck (repair).
1.
The cylinder gaskets are worn (repair the cylinder).
2.
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).
2.
ENGLISH
RS 501 33015500(3)2008-02
25
ENGLISH
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).
3.
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.
5.
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.
7.
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.
26
33015500(3)2008-02 RS 501
SERVICE MANUAL
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)
T
A
ENGLISH
D
DCB
F
E
U
H
G
K
L
J
I
S300862
RS 501 33015500(3)2008-02
27
ENGLISH
SERVICE MANUAL
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)
NMPO
V
R
S300863
28
33015500(3)2008-02 RS 501
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