Nilfisk Advance America Rs 501 Users Manual 33015499(3)2008 02

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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

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GENERAL INFORMATION
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.

OTHER AVAILABLE MANUALS
The following Manuals are available at Nilfisk Literature Service Department:
–
RS 501 Spare Parts List – Nilfisk Form Number 33015502
–
RS 501 User Manual – Nilfisk Form Number 33015501

SAFETY
The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary
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
Specific 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, flammable and/or explosive powders, liquids or vapors.
–
Be careful, fuel is highly flammable.
–
Do not smoke or bring naked flames in the area where the machine is refuelled or where the fuel is stored.
–
Refuel outdoors or in a well-ventilated area, with the engine off.
–
Do not fill the fuel tank to the top, but leave at least 4 cm from the filler neck to allow the fuel to expand.
–
After refuelling, check that the filler cap is tightly closed.
–
If any fuel is spilled while 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 affixed 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
–
fire.
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 filter 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)

Certified 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

/

Turquoise
blue

Density at 15°C

kg/l

1.13

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

REFERENCE DATA

SAE QUALITY

/

15W40

ACEA E3-96

Viscosity at 100°C

mm2/s

13.7

API Service CG-4/SG

Viscosity at 40°C

mm2/s

100

CCMC D5, PD-2

Viscosity at -15°C

mm2/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
mm2/s

Viscosity at 40°C

2

46

32

ISO-L-HV

45

32

ISO 11158

Viscosity at 100°C

mm /s

7.97

6.40

AFNOR NF E 48603 HV

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
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 defined 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

Running-in
period (after the
first 50 hours)

Every 10
hours or
before use

Every
200
hours

Every
600
hours

Every
1,200
hours

Every
2,400
hours

Engine oil level check
Engine air filter cleaning
Engine radiator fin cleaning check
Engine coolant level check
Battery fluid level check
Hydraulic system oil level and drain filter efficiency
check
Hydraulic system oil cooler fin check and cleaning
Hopper, filter and suction hose cleaning, and
gasket check
Dust control system nozzle and filter cleaning
Brake fluid 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
Side broom position check and adjustment
Engine oil change

(7)(8)

Dust control system water filter cleaning
Parking brake check
Alternator belt tension check

(7)

Climate control system compressor belt tension
check
Diesel engine oil filter replacement

(7)(8)

Fuel filter replacement

(7)

Nut and screw tightening and leakage check

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SERVICE MANUAL

GENERAL INFORMATION
Running-in
period (after the
first 50 hours)

Maintenance

Every 10
hours or
before use

Every
200
hours

Every
600
hours

Every
1,200
hours

Every
2,400
hours

Long
periods

Lubrication
Engine coolant line sleeve check

(7)

Drive system pump oil filter check
Hydraulic system oil drain filter replacement
Hydraulic system oil suction filter replacement
Alternator belt replacement

(3)

Cab air filter replacement

(1)

Injector calibration and cleaning

(2) (3)

Climate control system belt replacement
Engine coolant change

(3)

Hydraulic system oil change

(3)

Brake system check
Hydraulic system pump pressure check
Minor engine overhaul

(2) (4)

Major engine overhaul

(2) (5)

(1)
(2)
(3)
(4)
(5)
(7)
(8)

Or every 6 months
Maintenance to be performed by Lombardini authorised Service Center
Or every two years
After 5,000 hours
After 10,000 hours
Every year, if the machine is not frequently used
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 find 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.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.

Cab
Left door
Hopper
Diesel engine
Suction fan
Flashing light
Dust control system left tank
Front fixed wheels
Rear steering wheels
Right side broom
Left broom
Suction inlet
Right door
Meter and control panel
Rear axle
Dust control system right tank
Rear suction pipe (*)
Left lid
Left lid fasteners
Right lid
Right lid fasteners
Cab right panel
Cab left panel
Right door handle
Left door handle
Hopper lid
Open lid support rod
Lifted hopper locking pins
Lifted hopper locking pins housing
Lifted hopper locking pins holes
Suction filter
Drain filter
Hydraulic system oil tank
Battery
Hydraulic system oil cooler
Suction inlet-to-hopper pipe
Fuel tank
Hopper manual lifting hand pump (to be used in case of
engine malfunction)
Hydraulic system oil drain filter
Hopper lifting device
Dust control system left tank
Left tank mounting screw
Dust control system right tank
Right tank mounting screw
Front towing hook
Engine air filter
Fuel tank filler neck
Hopper support rods
Left water tank filler plug
Right water tank filler plug
Brake fluid tank
Windscreen wiper fluid tank
Windscreen wiper motor
Combination switch
Steering wheel adjusting lever
Drive pedal
Brake pedal
Steering wheel
Driver’s seat
Suction inlet and brooms control lever

RS 501

61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.

Driver’s seat safety belt (*)
Hopper lifting/lowering lever
Suction activation lever
Cab heater control knob
Diesel engine throttle lever
Parking brake lever
Broom dust control system nozzle valve
Suction inlet dust control system nozzle valve
Skirt lifting switch
Lifted hopper warning light (red)
Hazard warning light switch
Dust control system switch
Cab blower switch
Windscreen wiper/washer switch
Climate control system switch (*)
Ignition key
Dust control system water tank warning light (red)
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 first 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
98. Diesel engine serial number/technical data plate (another
plate showing the same data as the plate affixed on the
diesel engine)(*)
99. High-pressure washing system hose with reel (*)
100. High-pressure water quick coupling (*)
101. Breather filter hood fasteners
102. Rear suction pipe fastener
103. Front skirt
104. Machine serial number
105. Hopper (dumping position)
106. Suction hose gasket

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GENERAL INFORMATION
107. Hopper manual lifting hand pump lever
108. High-pressure water gun
109. Serial number plate/technical data/certification marking
110. Right water tank drain plug
111. Left water tank drain plug
112. High-pressure washing system pressure gauge
113. Breather filter hood
114. Hydraulic system oil filler plug
115. Hydraulic system pressure intake (on drive system pump)
116. Hydraulic system pressure intake (at suction fan pump)
117. Hydraulic system pressure intake (at accessory and
steering system pump)

118. Hopper lid suction sealing gasket
119. Document holder
120. Hopper lifting/lowering lever safety flange
121. Suction inlet and broom lifting/lowering lever safety flange
122. Driver’s seat forward/backward adjustment lever
123. Ashtray
124. High-pressure water gun sprinkler nozzle
125. Cigarette lighter
126. Can holder
127. Broom speed adjuster (***)
128. Hydraulic system oil level indicator
(*) Optional for some countries.

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GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)

18

14

1

99

100

45

104

112
19
12 103
25
10
111
7

11

113

101

3

2

8

20

6

13
115

17
102
24
21

26

98
9
8
97

15

4
9

110

16
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GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)

5

105
48

26
40

32

28
27

31

46

30

29

118
47

38

39

114

106

128
33

36
107

37
51
41

49

44

42

50

35 43
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GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)

58

119

108

54
59
61

65

55

66
60

64

62

68
67

63

69

53

57

121
120

52

123
109

22

122

56

124

125
116

126
117

34

23

127

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GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)

78
1
70

80

79

81

77

71

73

74

72

83

82

75

96

76

84

95

85

94
93

86
87
88

92
91

89

90
S301407

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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
C

B

A

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

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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
1. Check the side brooms for proper height and tilting, according to the following procedure:
• 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 specification, according to the following procedure.
2. Engage the parking brake with the lever (66).
3. Turn the ignition key (76) to OFF position and remove it.
Broom height adjustment
4. 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.
5. Perform step 1 again.
Broom forward tilting angle adjustment
6. On both sides of the machine, loosen the screws (E) and (F), then adjust the forward tilting angle (G).
When the adjustment is completed, tighten the screws (E) and (F).
7. Perform step 1 again.
Broom side tilting angle adjustment
8. On both sides of the machine, loosen the screws (I) and (L), then adjust the side tilting angle (H).
When the adjustment is completed, tighten the screws (I) and (L).
9. Perform step 1 again.
Broom side position adjustment
10. The purpose of this adjustment is to improve the side position of the brooms as to the suction inlet (12).
11. To perform the adjustment, loosen the nuts (J) and operate on the screw (K), thus changing the side position of the brooms.
12. When the side brooms are too worn out, the adjustment is not possible; replace the brooms according to the instructions in the
relevant paragraph.

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SWEEPING SYSTEM
SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues)

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SWEEPING SYSTEM
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.
2.
3.
4.
5.
6.
7.

Lift the brooms and engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the centre screw (A), then remove the broom (B) to be replaced. Recover the key.
Remove the screws (D), then remove the flange (E).
Install the flange (E) and secure it on the new broom with the screws (D).
Install the new broom (B) with the key, then tighten the centre screw (A).
Adjust the height of the new broom according to the procedure shown in the previous paragraph.

D
B

B

B

A

E

D
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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.
3. Connect a speed measurement indicator with a portable tachometer to the broom (10) or (11).
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.

B
A
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DUST AND DEBRIS COLLECTION SYSTEM
DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION
The dust and debris collection system consists of:
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
N)
Q)

Suction fan
Dust and debris suction filter
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 filter
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 filters having the following functions:
The suction filter (B) retains dust and debris during fan suction phase, and makes them settle in the hopper;
–
The breather filter (N) retains dust and debris escaped from the suction filter, and does not allow them to be discharged
–
externally.
Both filters 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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DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION (Continues)

A
N
G
B

D

E

C

I

F

P
K
J

O
K

K
H
M

Q
L

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DUST AND DEBRIS COLLECTION SYSTEM
TROUBLESHOOTING
The suction fan turns but it is not efficient
Possible causes:
1. The filters are clogged (clean).
2. The suction hose is clogged (clean).
3. The suction hose is cut/torn (replace).
4. The gasket between the suction inlet and the hopper is broken or misadjusted (replace or adjust).
5. The hopper lid gasket is broken (replace).
6. There is no pressure at the suction fan motor drive pump (adjust the pump pressure).
The suction fan does not turn
Possible causes:
1. The motor is faulty (replace).
2. The control valve assembly is stuck (repair).
3. The pump is faulty (replace).
The suction inlet does not collect debris efficiently
Possible causes:
1. The suction inlet position is incorrect (check the suction inlet and skirt height and efficiency).
The skirt opening force is not sufficient
Possible causes:
1. The skirt opening pressure is incorrect (adjust).
The hopper does not lift/lower
Possible causes:
1. The control valve assembly is stuck (repair).
2. The cylinder gaskets are worn (repair the cylinder).
The rear lid does not open/close
Possible causes:
1. There is no voltage in the actuator (repair the electrical system).
2. The actuator is faulty (repair/adjust the actuator cams).

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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
1. Empty the hopper (3), drive the machine to a cleaning/washing appointed area, then engage the parking brake with the lever
(66).
2. Lift and dump the hopper (3), according to the procedure shown in the User Manual.
3. Install the lid support rod (27).
Hopper cleaning
4. Clean the hopper (H) with pressurised water from a hydrocleaner (G).
5. Carefully check the suction sealing gasket (U) for integrity, and replace it if necessary.
Suction hose cleaning
6. Thoroughly clean the suction hose (R) inside, up to the suction inlet, with pressurised water.
7. Carefully check the suction sealing gasket (V) for integrity, and replace it if necessary.
Suction filter cleaning
8. Inside the hopper, remove the suction filter fastener (A).
9. Remove the suction filter (B).
10. Wash the deflector (C) and the fan (D) with pressurised water; check that all fan sectors (T) are clean.
11. Clean the suction filter (F) with pressurised water from a hydrocleaner (E).
12. Install the suction filter (B) and secure it with the fastener (A).
13. Remove the lid support rod (27) and lower the hopper (3) according to the procedure shown in the User Manual.
14. Turn the ignition key (76) to OFF position and remove it.
Breather filter cleaning
15. With a ladder and the help of an assistant, disengage the fasteners (I) of the breather filter hood (J).
16. Open the hood (K) and install the safety pin (L).
17. Remove the mounting screws (M), then remove the breather filter (N).
18. Clean the breather filter (P) with pressurised water from a hydrocleaner (O).
19. Install the breather filter and its hood performing steps from 15 to 17 in reverse order.

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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)

D

T

A

B

C

D

F
E

U

H

G
K
L

J
I

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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)

M

N

O

P

V

R
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DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK
Preliminary operations
1. Engage the parking brake with the lever (66).
2. Lift the suction inlet (12), according to the procedure shown in the User Manual.
3. Turn the ignition key (76) to OFF position and remove it.
Suction inlet wheel check
4. Check that the three wheels (A) of the suction inlet are in good conditions and turn freely (they must not be bent/misshapen
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
5. 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
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 difficult 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
6. Check that the skirt (I) is integral and that it does not have excessive tears (J) or lacerations (K), which can affect the suction
inlet operation.
If necessary replace the skirt (I) (see the procedure in the relevant paragraph).
7. Drive the machine on a level ground and lower the suction inlet (12) according to the procedure shown in the User manual.
8. Turn the ignition key (76) to OFF position and remove it.
9. Check that the distance (L) of the skirt from the ground is not bigger than 1 cm. Greater distances can affect the suction inlet
operation.
If necessary replace the skirt (K) (see the procedure in the relevant paragraph).
10. Also check that, when the three wheels (A) contact the ground, the sliding panels (C), (D), (E), and (H) do not touch the
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).
11. Start the machine according to the procedure shown in the User Manual, then press the switch (69) and check that the skirt
(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
12. Assemble the components in the reverse order of disassembly.

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DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK (Continues)

G C

A

G

H A
B

E

F

D

G

F

L

J

A
I

K

N

O

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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
1. Engage the parking brake with the lever (66).
2. Lift the suction inlet (12), according to the procedure shown in the User Manual.
3. Turn the ignition key (76) to OFF position and remove it.
4. On both sides of the machine, loosen the screws (E) and (F), then remove the front wheels (A) and (B).
5. Install the new front wheels (A) and (B) and fasten them with the screws (E) and (F).
6. 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
7. 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).
8. Remove the screws (E), (F) and (G), then remove the wheels (A), (B) and (C).
9. 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).

A

E

C

D

G

B
F
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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.
1.
2.
3.
4.

5.
6.

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 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).

F

E

D

B

F

A

C

C
A
F
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DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET DISASSEMBLY/ASSEMBLY
Disassembly
1. Remove the side brooms (see the procedure in the relevant paragraph).
2. Lower the suction inlet (12), according to the procedure shown in the User Manual.
3. Engage the parking brake with the lever (66).
4. Turn the ignition key (76) to OFF position and remove it.
5. Disconnect the hydraulic system hoses (A) and (B) from the suction inlet (C) and plug them.
6. Disconnect the dust control system water hose (D).
7. Remove the nuts (E) and pins (F).
8. Move the suction inlet (C) forward, and loosen the suction hose clamp (G).
9. Disconnect the suction hose (H) from the suction inlet.
10. Remove the suction inlet (C).
Assembly
11. Assemble the components in the reverse order of disassembly.
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).

F

H

B
A
G
D
E
E

F

C

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DUST AND DEBRIS COLLECTION SYSTEM
SKIRT REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

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.

B
A

C

D

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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER POSITION ADJUSTMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

14.
15.
16.
17.

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).
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Loosen the locknuts (A).
Insert a lever into the holes (C), then turn the rods (B) as necessary.
Remove the locking pins (28) and place them into the holes (29).
Lower the hopper (3), according to the procedure shown in the User Manual, and check that the profiles (D) match the frame
profiles (E).
If necessary, perform steps 4, 5, 6, 8, 9 and 10 again.
Then perform steps 3, 4, 5 and tighten the locknuts (A).
Lower the hopper (3), according to the procedure shown in the User Manual, and check that the hopper suction hole (F) match
the suction hose gasket (G). If necessary, adjust the position of the suction hose (H) according to the procedure shown in the
following steps.
Perform steps 4, 5 and 6 again.
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
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
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.

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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER POSITION ADJUSTMENT (Continues)

D

D
A
B

A

C

B
C
E
E

F

G
I

H

J
L

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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER LID CLOSING ACTUATOR ADJUSTMENT
Preliminary operations
1. Empty the hopper (3), according to the procedure shown in the User Manual.
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 right lid (20) by releasing the fasteners (21) with the supplied key.
6. Remove the locking pins (28) from the housings (29) and place them into the holes (30).
7. 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
8. According to the procedure shown in the User Manual, turn the safety hook (D) of the lid (E) to closing position (as shown
in the figure); in this condition, loosen the security dowel (F) of the cam (G), and then turn the cam until the microswitch (H)
activates.
Open safety hook warning light adjustment
9. When the safety hook (D) of the lid (E) is turned to closing position (as shown in the figure), loosen the security dowel (I) of the
cam (J), and turn the cam until the corner (K) causes the microswitch (L) to activate and the warning light to turn off.
Lid safety hook opening end-of-stroke adjustment
10. 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
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.
11. To check the cam proper adjustment, open and close the hook (D) several times.
Reset
12. Perform steps 3 to 7 in the reverse order.

C

B

R

A
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DUST AND DEBRIS COLLECTION SYSTEM
HOPPER LID CLOSING ACTUATOR ADJUSTMENT (Continues)

P
Q

G

F

I

N

J

H

L

D

O

E

K
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DUST AND DEBRIS COLLECTION SYSTEM
MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY
Disassembly
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. With a ladder and the help of an assistant, disengage the fasteners (A) of the breather filter hood (B).
4. Open the hood (C) and install the safety pin (D).
5. Remove the mounting screws (E), then remove the breather filter (F).
6. Disconnect the hoses joints (G) and (H) from the suction fan motor (I).
7. Remove the mounting nuts (J) of the flange (M).
8. With an appropriate hoisting system, remove the suction fan motor assembly (K) by removing the silicone along the perimeter
(L) of the flange (M), then sling the assembly (K) by placing a rope around the motor (I) and the fittings (N).
9. At the workbench, remove the screw (O) and the fan (P).
10. Remove the nuts (Q) from the screws (R).
11. Remove the motor (I) from the flange (M).
Assembly
12. Assemble the components in the reverse order of disassembly and note the following:
• Remove the silicone along the perimeter (L) of the flange (M) and from the flange housing on the hopper.
• Apply new silicone along the perimeter (L) of the flange (M).

B

E

A

C

D

F

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DUST AND DEBRIS COLLECTION SYSTEM
MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues)

Q

N
H
N
G
J
K
M

L
R
P

O

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DUST AND DEBRIS COLLECTION SYSTEM
SUCTION HOSE DISASSEMBLY/ASSEMBLY
Preliminary operations
1. 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 right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
6. Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Disassembly
7. Loosen the clamp (A) and disconnect the suction hose (B) from the suction inlet (C).
8. Loosen the left and right side mounting screws (D) of the suction hose upper end (E).
9. Remove the suction hose (F) by pulling it upwards.
Assembly
10. Assemble the components in the reverse order of disassembly and note the following:
• For a easier installation of the suction hose (B) into the suction inlet (C), apply a thin coat of grease on the sliding parts.

B

D

F
E

D
D

A

C
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DUST AND DEBRIS COLLECTION SYSTEM

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DUST CONTROL SYSTEM
DUST CONTROL SYSTEM
DESCRIPTION
The dust control system consists of:
A) Right water tank
B) Left water tank
C) Tank filler plugs
D) Broom nozzles
E) Suction inlet nozzles
F) Water filter
G) Hose
H) Water level indicator
Nozzle pump
I)
J) Taps
K) Rear suction pipe nozzle
L) Opening tap
M) Tank drain plugs
The water gun connected to the dust control system consists of:
N) Water gun pump
O) Quick coupling
P) Water gun
Q) Hose
R) Reel
S) Pressure gauge

Q

R

O
S

C
D

A

B

P

E

M

G
J

I
I

B

F

J

D

E

J

J

N
E

O
C
K

K

D

D

P

L

A
F

N

M

H
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DUST CONTROL SYSTEM
TROUBLESHOOTING
No water from the nozzles
Possible causes:
1. The water filter is clogged (clean/replace).
2. The nozzles are clogged (clean).
No water to the nozzles
Possible causes:
1. The water pump relay is burned (replace).
2. The pump does not work (repair/replace).

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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
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
Cleaning of nozzles and filters on brooms
3. Unscrew the ring nuts (A).
4. Clean the nozzles (B) and filters (C) with compressed air. Remove calcium deposits. If necessary, replace the filters (C).
5. Install the filters and nozzles, and secure them with the ring nuts. Nozzle holes must be directed down when tightening.
Cleaning of nozzles inside the suction inlet
6. On both sides of the suction inlet (D), remove the screws (E) together with the nozzles (F).
7. Clean the nozzles (F) and screws (E) with compressed air. Remove calcium deposits.
8. Assemble the components in the reverse order of disassembly.
Cleaning of nozzle and filter in the rear suction pipe
9. Remove the screw (G), the nozzle (H) and the filter (I).
10. Clean the nozzle (H) and filter (I) with compressed air. Remove calcium deposits. If necessary, replace the filter (I).
11. Assemble the components in the reverse order of disassembly.

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DUST CONTROL SYSTEM
NOZZLE AND FILTER CLEANING (Continues)

C
A

B
A

E
E

D
F

F

H
I
G

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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 filter is removed, the water inside the tanks comes out up to the filter level.
Preliminary operations
1. Turn the ignition key (76) to OFF position and remove it.
2. Engage the parking brake with the lever (66).
3. In the area over the rear axle (15), remove the water filter cover (A) together with the filter (B).
4. Separate the filter (B) from the cover (A), then wash and clean it. If necessary, replace the filter (B).
5. Install the filter (B) and the cover (A).
6. If necessary, fill the water tanks.

B
A

A
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DUST CONTROL SYSTEM
WATER TANK EMPTYING
When necessary, empty the dust control system water tanks (7 and 16) according to the following procedure.
1. Turn the ignition key (76) to OFF position and remove it.
2. Engage the parking brake with the lever (66).
3. Remove the water tank drain plugs (A) and (B) and drain all the water from the tanks.
4. Install the plugs (A) and (B).

A

B

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STEERING SYSTEM
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
B) Priority valve
C) Steering gearbox
D) Rear wheel control hydraulic cylinder
E) Hydraulic system oil tank
F) Hydraulic system hoses

E

D
C

B

A

F
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STEERING SYSTEM
TROUBLESHOOTING
The machine does not move straightforward
Possible causes:
1. The rear axle toe-in is incorrect (adjust).
The steering is hard
Possible causes:
1. The steering gearbox is faulty (replace).
2. The priority valve is faulty (replace).
3. The rear wheel control hydraulic cylinder is faulty (replace).

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STEERING SYSTEM
REAR AXLE TOE-IN ADJUSTMENT
1.
2.
3.
4.

5.

Drive the machine on a solid and level ground and keep the rear wheels (A) in a straightforward position, then engage the
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 figure.
Do not place the plates (B) where the tire surface is irregular.
Keeping the plates (B) in the above-mentioned position, check that the distances (E) and (F), measured on the front and on
the back of the wheels (A), are the same. A maximum difference 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).

B

A

E
A

B

F

B

A

B
A
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STEERING SYSTEM
REAR AXLE TOE-IN ADJUSTMENT (Continues)

C

C

D

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

G
C

A
H

B

E
E

E

I

I

D

F

D
F
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BRAKE SYSTEM
TROUBLESHOOTING
The machine brake system is not efficient
Possible causes:
1. The brake fluid is insufficient (check the fluid level).
2. The brake fluid pump is faulty (overhaul).
3. There is air in the system (bleed).
4. The drum brake cylinder is faulty (replace).
5. The braking masses are worn or greasy (replace).
The parking brake is not efficient
Possible causes:
1. The brake is misadjusted (adjust).

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BRAKE SYSTEM
BRAKE FLUID LEVEL CHECK
1.
2.
3.

5.

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

A

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BRAKE SYSTEM
PARKING BRAKE CHECK AND ADJUSTMENT
Check
1. 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
2. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
3. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
4. Lift the hopper (3), according to the procedure shown in the User Manual.
5. Turn the ignition key (76) to OFF position and remove it.
6. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
7. Remove the locking pins (28) from the housings (29) and place them into the holes (30).
8. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
9. 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.
10. Operating under the parking brake lever (66), adjust the brake control cables according to the following procedure depending
on the type of adjustment (same adjustment for both wheels, or 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

I
I

E

B

C
F

G
H
D
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BRAKE SYSTEM
PARKING BRAKE CONTROL CABLE REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Operating under the parking brake lever (66), unscrew the locknuts (C) and (D), disconnect the control cable (E) or (F) and
recover the relevant spring (G).
Remove the front wheel (see the procedure in the relevant paragraph).
Place safety stands under the machine side sill.
Remove the screw (H) and the screws (I), then remove the washer (J).
Remove the drum (K).
Remove the three springs (L).
Remove the shoe retaining springs (M).
Remove the shoes (N) by disengaging the parking brake control cable (O) from the lever (P).
Perform steps 3 to 6 and 8 to 16 in the reverse order.
Adjust the parking brake (see the procedure in the relevant paragraph).
If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

E
F

D

G

C
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BRAKE SYSTEM
PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues)

H

I

K

L

P

O
M
M

N

N

L

L

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BRAKE SYSTEM
BRAKE SYSTEM CHECK
1.
2.
3.
4.
5.

Check the brake fluid level (see the procedure in the relevant paragraph).
Press the brake pedal (57) several times, and check that brakes operate properly.
Check that there are no leaks from the brake system.
If necessary, check/replace the brakes (see the procedure in relevant paragraph).
If necessary, bleed the brake system (see the procedure in the relevant paragraph).

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BRAKE SYSTEM
BRAKING MASSES REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Remove the front wheel (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 screw (A) and the screws (B), then remove the washer (C).
Remove the drum (D).
Remove the three springs (E).
Remove the shoe retaining springs (F).
Remove the shoes (G) together with the braking masses, by disengaging the parking brake control cable (H) from the lever (I).
Perform steps 1 to 7 in the reverse order.

C
A

B

D
E
I

H
F
F

G
G
E
E
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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.
1.
2.
3.
4.
5.

6.
7.

Check the brake fluid 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 fluid.
Press the brake pedal (57) until the pedal resistance increases. In this condition, keep the pedal pressed and unscrew the
valve (A) slightly. Let the oil and air bleed from the pipe (B) into the container (C) until no more air comes out, but oil only. Then
screw down the 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.

B

A

C
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BRAKE SYSTEM

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DRIVE SYSTEM
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
B) Right drive system motor
C) Left drive system motor
D) Drive system pump
E) Hydraulic system oil tank
F) Hoses

E

D
C

B

A

F
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DRIVE SYSTEM
TROUBLESHOOTING
The machine stability is reduced
Possible causes:
1. The tires are not correctly inflated (check tire pressure).
The rear axle is noisy
Possible causes:
1. The wheel bearings are worn (replace).
The machine power is reduced
Possible causes:
1. The drive system motors are worn (replace).
2. The drive pedal is faulty (replace).
3. The drive system pump power decreases (check the oil pressure at the drive system pump).
The machine does not move
Possible causes:
1. The drive system pump deactivation screw for machine pushing/towing is unscrewed (screw down).
2. There are oil leaks from the hydraulic system (repair).
3. The drive system pump is broken (replace).
4. The drive system motor is broken (replace).
The machine moves even if the drive pedal is released
Possible causes:
1. The drive pedal is misadjusted (adjust).

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DRIVE SYSTEM
TIRE PRESSURE CHECK
1.
2.
3.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
The tire pressure should be as follows:
• Front tires:
3.75 Bar
• Rear tires:
3.75 Bar

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DRIVE SYSTEM
REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR
ADJUSTMENT
Check
1. Check that, when the machine moves in reverse, the relevant buzzer sounds.
If necessary, adjust the relevant sensor according to the following procedure.
Adjustment
2. Engage the parking brake with the lever (66).
3. Turn the ignition key (76) to OFF position and remove it.
4. Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
5. 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).
6. Perform step 1 again.

F

A

C
D

G

E

B

E

H
G
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DRIVE SYSTEM
REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY
Disassembly
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. Cut the cable clamp (A) under the right side of the cab.
4. Disconnect the reverse gear buzzer activation sensor connector (B).
5. Remove the four mounting screws (D) of the drive pedal (E).
6. Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).
7. Remove the sensor (C), the harness (G) and the connector.
Assembly
8. Assemble the components in the reverse order of disassembly.
9. Adjust the reverse gear buzzer activation sensor (see the procedure in the relevant paragraph).

A

A

B

F

E

C

G

D
C
D
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DRIVE SYSTEM
WHEEL REMOVAL/INSTALLATION
Preliminary operations
1. Turn the ignition key (76) to OFF position and remove it.
2. Engage the parking brake with the lever (66).
3. Check that the machine cannot move with one wheel lifted (the parking brake operates only on the front wheels). If necessary
keep the machine stationary by placing wedges on the wheels contacting the ground.
4. Remove the wheel according to the following procedure.
Rear wheel removal/installation
5. Place the jack (A) (not equipped) under the relevant housing (D) in the rear axle (B), as shown in the figure.
6. Carefully activate the jack (A), and lift the wheel (C) until it is slightly detached from the ground.
7. Remove the mounting nuts, then remove the wheel (C).
8. Install the wheel (C) by performing steps from 5 to 7 in the reverse order.
Wheel mounting nut tightening torque: 400 N·m
Front wheel removal/installation
9. 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 figure.
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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DRIVE SYSTEM
DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove the suction inlet (see the procedure in the relevant paragraph).
Remove the front wheel (see the procedure in the relevant paragraph). Place safety stands under the machine side sill, on the
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 five screws (G), then remove the drive system motor (B) together with the brake.
Assemble the components in the reverse order of disassembly and note the following:
• Before assembling the wheel, bleed the brake system (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).

D

B

G
A

E

B

C

F

G
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DRIVE SYSTEM
DRIVE PEDAL CHECK AND ADJUSTMENT
Preliminary operations
1. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Check
2. Drive the machine on a level and smooth ground, and, with the engine on, check that the machine does not move forward or
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
3. Engage the parking brake with the lever (66).
4. Turn the ignition key (76) to OFF position.
5. 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
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
6. Disengage the parking brake with the lever (66).
7. Stop the left front wheel with two wedges (A).
8. Remove the right front wheel according to the procedure shown in the relevant paragraph.
9. Place safety stands under the machine side sill, on the side where the wheel has been removed.
10. Lift the hopper (3) for 20 cm, according to the procedure shown in the User Manual.
11. Turn the ignition key (76) to OFF position and remove it.
12. Open the right lid (20) by releasing the fasteners (21) with the supplied key.
13. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
14. 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.
15. Turn on the diesel engine with care.
WARNING!
When the diesel engine is running, the wheel hub (B) can be rotating.
16. Check that the machine is in the following conditions:
• 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).
17. Engage the parking brake with the lever (66).
18. Turn the ignition key (76) to OFF position.
19. Perform steps 6 to 12 in the reverse order.
20. Perform step 1 again.
21. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

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DRIVE SYSTEM
DRIVE PEDAL CHECK AND ADJUSTMENT (Continues)

A

B
C
D
E

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DRIVE SYSTEM

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LDW 1603/B2 ENGINE
LDW 1603/B2 ENGINE
DESCRIPTION
The machine is equipped with a diesel engine, which activates the hydraulic system pumps.
For diesel engine data see the Technical Data chapter and the Diesel Engine Manual.
The following pumps are connected to the engine:
A) Accessory and steering system pump
B) Suction fan pump
C) Drive system pump
The fuel filter is located on the machine frame.
For machines equipped with climate control system, besides the alternator control pulley, there is also the compressor control pulley
(D).

A

B

C

D
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LDW 1603/B2 ENGINE
TROUBLESHOOTING
The diesel engine does not start
Possible causes:
1. The drive pedal is pressed (release).
2. The sensor for engine start-up inhibition is misadjusted/broken (adjust/replace).
NOTE
For diesel engine complete troubleshooting, see the relevant Manual.

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LDW 1603/B2 ENGINE
ENGINE OIL LEVEL CHECK
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (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.

9.
10.
11.
12.

Check the oil level according to the procedure shown in the Diesel Engine Manual.
If necessary, add oil according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ENGINE OIL CHANGE
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Change 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ENGINE OIL FILTER CHANGE
NOTE
This procedure must be performed when the engine oil has been drained.
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Replace the oil filter 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ENGINE COOLANT LEVEL CHECK
1.
2.
3.
4.
5.
6.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
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.

7.

Check that the coolant level in the tank (A) is between the minimum and maximum marks, according to the procedure shown
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.

8.

B

A
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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
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
Pre-filter cleaning
4. Remove the screw (A), then remove the pre-filter (B).
5. Clean and wash the pre-filter, then install it.
Filter cleaning
6. Remove the screw (C), then remove the cover (D).
7. Remove the outer filter (E) and the inner filter (F).
8. Clean the filters (E) and (F) carefully with compressed air (maximum 6 Bar) and replace them, if necessary.
9. Install the filters (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.

A

C

B

E

D

F

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LDW 1603/B2 ENGINE
FUEL FILTER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Replace the fuel filter 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
FUEL FITTING AND SCREW CHECK
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9.
10.
11.
12.

Operating on the fuel filter (A) and on the diesel engine, check the sealing of fuel system fittings (B). Repair if necessary.
Operating on the fuel tank (C), check the sealing of fuel system fittings (D). Repair if necessary.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

B

B

D

C
B

B

A

B B

D
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LDW 1603/B2 ENGINE
ALTERNATOR BELT TENSION CHECK
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Check and, if necessary, adjust the alternator belt tension 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ALTERNATOR BELT REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Replace and adjust the alternator belt tension 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
RADIATOR FIN CLEANING CHECK
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
On both sides of the machine, loosen the screws (42 and 44), and open the right and left tanks (41 and 43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Check the radiator fin cleaning 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ENGINE COOLANT LINE SLEEVE CHECK
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screws (44) and (42) and open the right (43) and left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Check the coolant line sleeves 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
ENGINE COOLANT CHANGE
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
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.

9. Change the engine coolant 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, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE
INJECTOR CALIBRATION AND CLEANING
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Calibrate and clean the injectors according to the procedure shown in the Diesel Engine Manual.
10. Perform steps 3 to 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

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LDW 1603/B2 ENGINE

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CLIMATE CONTROL SYSTEM
CLIMATE CONTROL SYSTEM
DESCRIPTION
The climate control system consists of:
A) Compressor
B) Condenser
C) Cooler
D) Expansion valve
E) Filter drier
F) High pressure hose
G) Low pressure hose
H) High pressure connection
Low pressure connection
I)
J) Cooling controls
K) Heating controls
L) Heater
M) Air filter

J

B

E

F

K
L

H

G

I

A

D
M

C
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CLIMATE CONTROL SYSTEM
TROUBLESHOOTING
No fresh air from the climate control system
Possible causes:
1. The compressor does not turn because the drive belt is loosen/broken (tension/replace the belt).
2. There are gas leaks from the system (repair the leak and integrate the gas).
3. The expansion valve is faulty (replace).
No hot air from the climate control system
Possible causes:
1. The hot water hoses are broken (replace).
2. There are water leaks from the heater (replace).

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CLIMATE CONTROL SYSTEM
COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine)
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

Check the tension of the belt (A) of the compressor (B) according to the following procedure:
• Press the belt in the intermediate 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).
10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.
9.

D

C

A

B

E
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CLIMATE CONTROL SYSTEM
COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine)
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9.
10.
11.
12.
13.
14.

Loosen the tensioning nuts (A) of the belt (B) of the compressor (C).
Remove the belt (B) from the pulleys.
Place the new belt (B) on the pulleys.
Adjust the compressor belt tension according to the procedure shown in the previous paragraph.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

B

A

C
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CLIMATE CONTROL SYSTEM
AIR FILTER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws (A) and the panel (B) in the cab.
Unscrew the knobs (F) and remove the panel (C).
Remove the cab air filter (D).
Install the new filter (D) with the arrows (E) pointing in the direction of the air flow (upwards).
Perform steps 3 and 4 in the reverse order.

A

A

B

A

F

C

F

A

D

E
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CLIMATE CONTROL SYSTEM

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OTHER SYSTEMS
OTHER SYSTEMS
NUT AND SCREW TIGHTENING AND LEAKAGE CHECK
1.
2.
3.
4.
5.
6.
7.
8.

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).
Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Remove the screw (42) and open the left tank (41).
10. Inspect the machine accessible parts and check for:
• Tightening of mounting screws and nuts;
• Correct position of the fasteners;
• Visible faults in the components;
• Leaks of fluids (oil, etc.).
11. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

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OTHER SYSTEMS
LUBRICATION
1.
2.
3.

Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Lubricate the rear axle knuckles with the grease nipples (A). If necessary, steer the rear wheels to reach the grease nipples
easily.
Grease quantity to be applied:
• 2 - 3 pumping, in case of a manual pump.
• 8 - 12 seconds of injection, in case of an air pump.

A
A

A

A

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OTHER SYSTEMS
CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE
PEDAL IS PRESSED
Check
1. 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
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
4. 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).
5. Perform step 1 again.

F

A

C
D

B

G
E
H
G
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OTHER SYSTEMS
DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE
PEDAL IS PRESSED
Disassembly
1. Engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. Cut the cable clamp (A) under the right side of the cab.
4. Disconnect the connector (B) of the sensor for engine start-up inhibition (C).
5. Remove the four mounting screws (D) of the drive pedal (E).
6. Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).
7. Remove the sensor (C), the harness (G) and the connector.
Assembly
8. Assemble the components in the reverse order of disassembly.
9. Adjust the sensor for engine start-up inhibition (see the procedure in the relevant paragraph).

A

A

B

E
F

C

G

D

D
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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
DESCRIPTION
The hydraulic system consists of three independent circuits, supplied by one tank.
The first circuit is supplied by a variable delivery pump, activated by the diesel engine. This pump activates two drive system
motors, which operate on the front wheels.
The forward and reverse drive speed is adjusted by the drive pedal, which is connected to the pump.
The second circuit is supplied by a gear pump, activated by the diesel engine. This pump activates the suction fan motor by means
of the control valve assembly.
The third circuit is supplied by a gear pump with priority valve, activated by the diesel engine. This pumps, by means of the control
valve assembly, performs the following functions:
Side broom motor activation
–
Hopper lifting and dumping
–
Suction inlet lifting and moving
–
Rear wheel control hydraulic cylinder activation (by means of the oil taken from the priority valve)
–
All circuits are protected by suction filters and safety valves.
NOTE
The hydraulic system hoses are DIN type.

COMPONENT LOCATION
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.

Hydraulic system oil tank
Drain filter
Suction filter
Suction filter
Drive system pump
Diesel engine
Left drive system motor
Control valve assembly
Right drive system motor
Skirt cylinder
Hopper lifting cylinder
Hand pump
Right side broom motor
Left side broom motor
Hydraulic system oil cooler
Parachute valve
Suction inlet and broom lifting cylinder
Check valve
Power steering
Flow separator (priority valve)
Accessory and steering system pump
Suction fan pump
Control valve assembly
Solenoid valve
Suction fan motor
Power steering cylinder
Drive pedal assist
Oil filter
Drive system pump oil filter
High-pressure washing system pump (*)
Flow regulator (*)
Hydraulic system oil filler plug
Hydraulic system oil level indicator

(*) Optional for some countries.

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HYDRAULIC SYSTEM
COMPONENT LOCATION (Continues)
51

61

81

82
50
69
52-53
76
64

74
57

72

79
75

58-73
80
65
62

67

70

66

68

56
59

71

55
54-78

63

60
65

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HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.

Hydraulic system oil tank
Drain filter
Suction filter
Suction filter
Drive system pump
Diesel engine
Left drive system motor (**)
Right drive system motor (**)
Control valve assembly
Skirt cylinder
Hopper lifting cylinder
Hand pump
Right side broom motor
Left side broom motor
Hydraulic system oil cooler
Parachute valve
Suction inlet and broom lifting cylinder
Check valve
Power steering
Flow separator (priority valve)
Accessory and steering system pump
Suction fan pump
Control valve assembly
Solenoid valve
Suction fan motor
Power steering cylinder
Drive pedal assist
Oil filter
Drive system pump oil filter
High-pressure washing system pump (*)
Flow regulator (*)
Breather/filler plug

(*) Optional for some countries.
(**) A version: 150 cc
B version, standard: 175 cc
C version: 200 cc

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11.23cc

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A

P

B

T

RS 501

64

A

P

USCITÀ ACQUA/
WATER OUTLET

B

71

14.1cc

B

L1

57

18bar

A

DX

M1

M2

10µm

77

A

50

A

250bar

250bar

54

52

60µm

a

A

A

b

A

51

P
T

53

55

70
1

21.8 l/min

69

2

A

3

A

68

T

90bar

P

80cc

13.1 l/min

A

62

A 130bar

A1

B1

8.7 l/min

80cc

40cc

63

58

CAPACITÀ SERBATOIO/TANK CAPACITY: 40.6 lt.(10.73 U.S. gal.) A
CAPACITÀ IMPIANTO/SYSTEM CAPACITY: 58 lt.(15.32 U.S. gal.)

1:1

2600 RPM
(MAX)

M

10µm

78

8.1cc

B

1:1

60µm

10µm

81

S

A

L2

9cc

P1

60µm

21cc

B

P

67

3

A

T

A2

B2

61

150bar

150bar

A

2

ASPIRAZIONE ACQUA/
WATER INLET

72

210bar

T

B

76

B

1

2

A

R

L

73 A

P

EV3

B

79

74

B

A

A

C2

66

80

0

56

SX

A

C1

40X95X 20
1

Versione [C] / [C] Version : 200cc

Versione [B] / [B] Version : 175cc
(Standard)

66

40X95X 20

60

2
3

N2

30bar

B
4
1

A

EV2

59

c

48X85

75

40X70X 25

65

50X350X 35

32

T

ENGLISH
SERVICE MANUAL

HYDRAULIC SYSTEM

HYDRAULIC DIAGRAM (Continues)

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HYDRAULIC SYSTEM
TROUBLESHOOTING
See the previous chapters related to the use of the hydraulic system.

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
1.
2.
3.
4.
5.
6.
7.
8.

Engage the parking brake with the lever (66).
Start the diesel engine and run it at 1,500 rpm, according to the procedure shown in the User Manual.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Check that the needle of the efficiency indicator (D) of the drain filter (C) is in the green area (E), otherwise the filter (C) must
be replaced (see the procedure in the relevant paragraph).
Check that there are no oil leaks in the upper area (F) of the hydraulic system oil tank.
Turn the ignition key (76) to OFF position and remove it.
Using the indicator (A), check that the oil level in the tank is between the MIN and MAX marks.
If necessary, unscrew the plug (G) and top up. For the types of oil to be used, see Technical Data chapter.
NOTE
Top up by using the same type of oil that is in the tank.

9. Screw down the plug (G).
10. Close the right lid (20) by engaging the fasteners (21) with the supplied key.

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL CHANGE
CAUTION!
This procedure must be performed with the hopper (3) fully retracted (as shown in the figure).
1.
2.
3.
4.
5.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

6.

Remove the oil drain hose (E) under the tank, then unscrew the plug (A), drain the oil and collect it into an appropriate
container.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil should be disposed of properly according to the environmental Laws in force.

Unscrew and remove the filler plug (B).
If necessary replace the drain filter (C) (see the procedure in the relevant paragraph).
Screw down the plug (A) and reinstall the oil drain hose (E) under the tank.
Pour oil in the tank (D) through the plug filler neck (B). For oil types and quantity, see the Technical Data chapter.
Fill the tank until the oil level reaches the MAX mark of the indicator (F).
11. Screw down the filler plug (B).
12. Close the right lid (20) by engaging the fasteners (21) with the supplied key.
13. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.
7.
8.
9.
10.

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL CHANGE (Continues)

A

E

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL SUCTION FILTER REPLACEMENT
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
1.
2.
3.

If necessary, bleed the hydraulic system oil from the tank (see the procedure in the relevant paragraph).
Remove the screws (A), then remove the tank cover (B) without damaging the gasket (E).
Unscrew and remove the suction filters (C) inside the tank.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in
force.

4.
5.
6.
7.
8.

Remove any debris and dirt from the tank.
Clean the tank upper perimeter edge (F) and the matching profile (D) of the cover (B).
Install the new filters (C) inside the tank.
Install the tank cover (B) and place the gasket (E) correctly; if necessary, replace it. Tighten the screws (A).
Pour the hydraulic system oil in the tank (see the procedure in the relevant paragraph).

C

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SERVICE MANUAL

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
1.
2.
3.
4.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Unscrew and remove the cover (A).
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in
force.

5.
6.
7.

Remove the drain filter (B) and replace it with a new one.
Install the cover (A).
Close the right lid (20) by engaging the fasteners (21) with the supplied key.

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HYDRAULIC SYSTEM
DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9.

Remove the screw (A) and the filter (B) behind the right front wheel.
If necessary, to reach the filter, remove the right front wheel according to the procedure shown in the relevant paragraph.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in
force.

10. Install a new filter (B) and fasten it with the screw (A).
11. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.

B

A
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SERVICE MANUAL

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed
air or water gun.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Clean the hydraulic system oil cooler fins (A) with compressed air (maximum 6 Bar). If necessary, point the compressed air in
the opposite direction of the cooling air.
Inside the radiator (A), check that the fan (B) turns freely.
Perform steps 3 to 6 in the reverse order.

B
A
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HYDRAULIC SYSTEM
REAR WHEEL CONTROL HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.

Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Disconnect the hoses (A) from the rear wheel control hydraulic cylinder (B) and plug them immediately.
Unscrew the fasteners (C) fixing the cylinder to the steering tie rods.
Remove the screws (D), then remove the cylinder (B).
Install the cylinder performing steps from 3 to 5 in the reverse order.
Adjust the rear axle toe-in (see the procedure in the relevant paragraph).
Check the hydraulic system oil level (see the procedure in the relevant paragraph).

A

A

D
D

C

B

C
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HYDRAULIC SYSTEM
HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
Disassembly/assembly of the following hydraulic cylinders:
Suction inlet right cylinder (A)
–
Suction inlet left cylinder (A)
–
Skirt cylinder (C)
–
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
1.
2.
3.
4.

Engage the parking brake with the lever (66).
Bring the suction inlet in the most suitable position.
Turn the ignition key (76) to OFF position and remove it.
Disconnect the hoses from the hydraulic cylinder and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

Disconnect and remove the hydraulic cylinder and, if necessary, support appropriately the components connected to the
cylinder.
6. Perform steps 2 to 5 in the reverse order.
7. Start the machine and check that the hydraulic cylinder operates properly, then stop the machine, check the hydraulic system
oil level and, if necessary, top up (as shown in the User Manual).
Disassembly/assembly of the following hydraulic cylinder:
Hopper lifting cylinder (D)
–
5.

1.
2.
3.
4.
5.
6.
7.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Disconnect the hoses from the hydraulic cylinder and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

Disconnect and remove the hydraulic cylinder and, if necessary, support appropriately the components connected to the
cylinder.
9. Perform steps 3 to 8 in the reverse order.
10. Start the machine and check that the hydraulic cylinder operates properly, then stop the machine, check the hydraulic system
oil level and, if necessary, top up (as shown in the User Manual).
8.

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HYDRAULIC SYSTEM
HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY (Continues)

A

C
B

D

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HYDRAULIC SYSTEM
SUCTION FAN CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION
CAUTION!
This procedure must be performed with the hopper (3) fully lowered.
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.

Remove the screws and the right panel (22) on the right side of the cab.
Disconnect all the hoses from the suction fan control valve assembly (A) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

3.
4.
5.
6.
7.
8.

Loosen the locknut (C) and remove the lever (B).
Remove the screws (D), then remove the control valve assembly (A).
If necessary, remove the fittings and the control valve assembly at the workbench.
Assemble the components in the reverse order of disassembly.
Check the hydraulic system oil level (see the procedure in the relevant paragraph).
Check the hydraulic system oil pressure at the suction fan pump (see the procedure in the relevant paragraph).

D

C

B

A

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HYDRAULIC SYSTEM
ACCESSORY SYSTEM CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION
CAUTION!
This procedure must be performed with the hopper (3) fully lowered.
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.
4.

If necessary, bleed the hydraulic system oil from the tank (see the procedure in the relevant paragraph).
Remove the screws and the right panel (22) on the right side of the cab.
Mark the position of the hoses connected to the accessory system control valve assembly (A) (for proper reassembly).
Disconnect all the hoses from the control valve assembly (A) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

Loosen the locknut (C) and remove the levers (B).
Remove the screws (D), then remove the control valve assembly (A).
If necessary, remove the fittings and the control valve assembly at the workbench.
Assemble the components in the reverse order of disassembly.
Pour oil in the tank (see the procedure in the relevant paragraph) until the level reaches the MIN mark of the indicator.
Start the machine, use the drive system and lift/lower the hopper a few times. Check that controls (60), (62) and (63) operate
properly. Then stop the machine, check the hydraulic system oil level and, if necessary, top up (as shown in the User Manual).
11. Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
5.
6.
7.
8.
9.
10.

B

C

D

A

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SERVICE MANUAL

HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
CAUTION!
This procedure must be performed with the hopper (3) fully retracted (as shown in the figure).
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Remove the retaining clamps (C) of the exhaust manifold (D), then move the exhaust manifold.
10. Mark the position of the hoses connected to the fittings (E) of the accessory pump (F) (for proper reassembly).
11. Disconnect the hoses from the fittings (E) of the accessory pump (F) and plug them immediately. Collect the hydraulic system
oil that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
Remove the screws (G), then remove the accessory pump (F) by disengaging the connecting joint.
If necessary, remove the accessory pump fittings at the workbench.
Assemble the components in the reverse order of disassembly.
Start the machine, lift/lower the hopper and activate the brooms a few times, then stop the machine, check the hydraulic
system oil level and, if necessary, top up (as shown in the User Manual).
16. Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
17. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.
12.
13.
14.
15.

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HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
(Continues)

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HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
(Continues)
CAUTION!
This procedure must be performed with the hopper (3) fully retracted (as shown in the figure).
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.
4.
5.
6.
7.
8.

Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the User Manual.
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.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: each tank contains 120 kg of water approximately.

9. Mark the position of the hoses connected to the fittings (E) of the accessory pump (F) (for proper reassembly).
10. Disconnect the hoses from the fittings (E) of the accessory pump (F) and plug them immediately. Collect the hydraulic system
oil that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
Remove the screws (G), then remove the accessory pump (F) by disengaging the connecting joint.
If necessary, remove the accessory pump fittings at the workbench.
Assemble the components in the reverse order of disassembly.
Start the machine, lift/lower the hopper and activate the brooms a few times, then stop the machine, check the hydraulic
system oil level and, if necessary, top up (as shown in the User Manual).
15. Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
16. If necessary, fill the dust control system water tanks according to the procedure shown in the User Manual.
11.
12.
13.
14.

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HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
(Continues)

C

C

E
G
F

G

G

E
G

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SERVICE MANUAL

HYDRAULIC SYSTEM
SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.

Remove the suction inlet (see the procedure in the relevant paragraph).
Mark the position of the hoses connected to the fittings (A) of the suction fan pump (B) (for proper reassembly).
Disconnect the hoses from the fittings (A) of the suction fan pump (B) and plug them immediately. Collect the hydraulic system
oil that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

4.
5.
6.
7.
8.

Remove the screws (C), then remove the suction fan pump (B) with the joint (D) and the relevant fasteners.
If necessary, remove the accessory pump joint (D) and fittings at the workbench.
Assemble the components in the reverse order of disassembly.
Start the machine, lift/lower the hopper and activate the suction fan a few times, then stop the machine, check the hydraulic
system oil level and, if necessary, top up (as shown in the User Manual).
Check the hydraulic system oil pressure at the suction fan pump (see the procedure in the relevant paragraph).

A
C
A
C

D
D
BB
S301424

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HYDRAULIC SYSTEM
DRIVE SYSTEM PUMP DISASSEMBLY/ASSEMBLY
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.

Remove the suction inlet (see the procedure in the relevant paragraph).
Mark the position of the hoses connected to the fittings (A) of the drive system pump (B) and of the suction fan pump (C) (for
proper reassembly).
Disconnect the hoses from the fittings (A) of the drive system pump (B) and of the suction fan pump (C), then plug them
immediately. Collect the hydraulic system oil that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.

4.
5.
6.
7.
8.

Remove the screws (E), then remove the pumps (B) and (C) with the relevant joints.
If necessary, remove the drive system pump fittings at the workbench.
If necessary, remove the screws (E), then remove the suction fan pump (C) with the joint (F) and the relevant fasteners.
Assemble the components in the reverse order of disassembly.
Start the machine, use the drive system and activate the suction fan, then stop the machine, check the hydraulic system oil
level and, if necessary, top up (as shown in the User Manual).
Check the hydraulic system oil pressure at the drive system pump (see the procedure in the relevant paragraph).

A
A

A

A

E

D B
F

C

A
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SERVICE MANUAL

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP
NOTE
This check is necessary in case of malfunction of the suction fan.
Preliminary operations
1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
3. Remove the screws and the right panel (22) on the right side of the cab.
4. Connect a pressure gauge (E), with a minimum scale of 250 Bar equipped with the extension, to the pressure intake (C).
5. Measure the suction fan pump pressure according to the following procedure.
Pressure measurement
6. Start the machine and run the engine at maximum speed (as shown in the User Manual). In this condition, turn the lever (F) to
“OPT” position and check that the pressure measured by the pressure gauge (E) is 220 Bar approximately.
• If the pressure is normal, disengage the lever (F) and turn off the machine.
• If the pressure is higher or lower, it can be adjusted according to the following procedure, while keeping the machine
accelerated and the lever (F) engaged.
Pressure adjustment
7. Unscrew the cap (G).
8. Loosen the locknut (H) and slightly turn the internal threaded dowel (I) to adjust the pressure. If the pressure cannot be
adjusted to normal values, probably the pump needs to be replaced (see the procedure in the relevant paragraph).
9. Disengage the lever (F) and turn off the machine.
10. Tighten the locknut (H) and screw down the cap (G).
Reset
11. Perform steps 3 and 4 in the reverse order.

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP (Continues)

F

C

G

E

H
I

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SERVICE MANUAL

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP
NOTE
This check is necessary in case of malfunction of the accessory system and steering system.
Preliminary operations
1. 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. Turn the ignition key (76) to OFF position and remove it.
4. Remove the screws and the right panel (22) on the right side of the cab.
5. Connect a pressure gauge (E) with a minimum scale of 150 Bar equipped with the extension.
6. Measure the accessory and steering system pump pressure according to the following procedure.
Pressure measurement
7. Start the machine and run the engine at maximum speed (as shown in the User Manual). In this condition, engage the lever
(F) to lift the hopper and check that the pressure measured by the pressure gauge (E) is 120 Bar approximately.
• If the pressure is normal, disengage the lever (F) and turn off the machine.
• If the pressure is higher or lower, it can be adjusted according to the following procedure, while keeping the machine
accelerated and the lever (F) engaged.
Pressure adjustment
8. Unscrew the cap (G).
9. Loosen the locknut (H) and slightly turn the internal threaded dowel (I) to adjust the pressure. If the pressure cannot be
adjusted to normal values, probably the pump needs to be replaced (see the procedure in the relevant paragraph).
10. Disengage the lever (F) and turn off the machine.
11. Tighten the locknut (H) and screw down the cap (G).
Reset
12. Perform steps 4 and 5 in the reverse order.

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ENGLISH

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP
(Continues)

C

F

G

E

H

I
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SERVICE MANUAL

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP
NOTE
This check is necessary in case of malfunction of the drive system.
Preliminary operations
1. 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 and engage the parking brake with the lever (66). To perform the inspection,
indicated in the next step 9, in a safe condition, the ground opposite the machine have to be free from obstruction and levelled.
3. Turn the ignition key (76) to OFF position and remove it.
4. Remove the screw (42), open the left water tank (7) and disconnect the fastener, then fully open the tank.
WARNING!
Open the left tank (41) only when it is empty: each tank contains 120 kg of water approximately.
Connect a pressure gauge (E), with a minimum scale of 300 Bar equipped with the extension, to the pressure intake (B) of the
drive system pump.
6. Measure the drive system pump pressure according to the following procedure.
Pressure measurement
7. Start the machine and run the engine at maximum speed (as shown in the User Manual).
8. Fully engage the parking brake with the lever (66).
WARNING!
To perform the inspection, indicated in the next step 9, in a safe condition, keep the personnel away from the
front of the machine and remove any obstructions.
5.

Press and hold the brake pedal (57), then fully press the drive pedal (56) (if the machine moves, release the drive pedal
(56), then try again by firmly pressing the brake pedal (57)). Check that the pressure on the pressure gauge (A) is within
200 and 250 Bar.
• If the pressure is normal, release the drive pedal (56) and turn off the machine.
• If the pressure is lower than specified, check if the fault is related to the drive system pump or to the drive pedal assist.
Reset
10. Perform steps 4 and 5 in the reverse order.
9.

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HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP (Continues)

A

B

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SERVICE MANUAL

HYDRAULIC SYSTEM

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ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
DESCRIPTION
The electrical system is power-supplied from the alternator, which is activated by the diesel engine.
The battery is 12 V.
Circuits are protected by lamellar fuses, which are located into appropriate fuse boxes.

COMPONENT LOCATION
NOTE
The abbreviation written before the component name refers to the wiring diagram (see the following pages).
A

Alternator

L3

Right front turn signal

AA

Horn

L4

Left rear turn signal

AS

Cigarette lighter

L5

Left brake light

B

12 V battery

L6

Right brake light

B1

Engine coolant temperature bulb

L7

Left front running light

B2

Engine oil bulb

L8

Right rear running light

B3

Engine coolant warning light bulb

L9

Right front running light

B4

Parking brake microswitch

L10

Left rear running light

B5

Lifted hopper microswitch

L11

Left low beam

B6

Brake light microswitch

L12

Right low beam

B7

Hydraulic system oil cooler fan bulb

L13

Left high beam

B8

Reverse gear sensor

L14

Right high beam

BX

Engine start safety sensor

L15

Flashing light

C1

Ignition switch

L16

Licence plate light

C2

Combination switch

M1

Starter

C3

Warning buzzer/parking brake buzzer

M2

Hydraulic system oil cooler fan motor

C4

Reverse gear buzzer

M3

Windscreen wiper motor

C5

Hour counter/revolution counter/water temperature indicator

M4

Dust control system water pump (normal)

C6

Climate control system compressor

M5

Cab blower motor

D1

Diode

M6

Climate control system blower motor

D2

Diode

M7

Windscreen washer motor with tank

EV1

Fuel solenoid valve

M8

Hopper lid opening/closing electric jack motor

EV2

Skirt solenoid valve

P

Climate control system pressure switch

EV3

Skirt solenoid valve

R1

Engine glow plug control unit relay

F1A

Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)

R2

General relay

F2A

Fuel solenoid valve fuse (10 A)

R3

Reverse gear buzzer relay

F3A

Cab blower/flashing light/windscreen wiper fuse (15 A)

R4

Turn signal intermittence relay

F4A

Dust control system water pump fuse (10 A)
Dust control system water pump/climate control system (optional) fuse
(20 A)

R5

Water pump relay

R6

Climate control system compressor relay (*)

R7

Climate control system condenser fan relay (*)

RS

Cab blower resistance

F5A

Reverse gear buzzer fuse (10 A)

F6A

Warning lights/glow plug control unit fuse (10 A)

F7A

Electric jack warning light fuse (10 A)

F8A

Hopper lid opening/closing electric jack fuse (15 A)

F1B

Hazard warning light fuse (10 A)

F2B

Brake light/horn fuse (10 A)

F3B

Left side running light fuse (10 A)

F4B

Right side running light fuse (10 A)

F5B

Low beam fuse (15 A)

F6B

High beam fuse (15 A)

F7B

Cigarette lighter fuse (20 A)

G1

Dust control system water level indicator

G2

Fuel level indicator

I1

Skirt lifting switch

I2

Hazard warning light switch

I3

Windscreen wiper/washer switch

I4

Water pump switch

I5

Cab blower switch

I6

Climate control system switch (2 speed/1 speed)

I7

Electric jack switch

L1

Left front turn signal

L2

Right rear turn signal

RX

Engine start safety relay

RY

Engine start safety relay

S1

Glow plug warning light

S2

Battery warning light

S3

Engine oil warning light

S4

Engine coolant warning light

S5

Parking brake warning light

S6

Lifted hopper warning light

S7

Running light indicator light

S8

High beam indicator light

S9

Hazard warning light indicator

S10

Turn signal indicator light

S11

Dust control system low water warning light

S12

Windscreen wiper warning light

S13

Dust control system water pump warning light

S14

Blower warning light

S15

Climate control system warning light

S16

Low fuel warning light

S17

Hopper lid opening/closing electric jack warning light

TM

Climate control system thermostat

K

Glow plugs

(*)

RS 501

Optional for some countries.

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ENGLISH

SERVICE MANUAL

ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)

L15

EV2-EV3

M2-B7
P
M8

M4

L4
L5
L10
L2
L6
L8

C4

L16

M6
G2

B5 G1

AS
AA

M7

B

L3
M5
RS
TM

C6
M1
EV1
K-A-B1-B2-B3 (*)

L9-L12-L14
L1
L7-L11-L13

S301503

(*)

See the Diesel Engine Manual

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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)

RY RX R7

R1

R6

R4

R3 R5 R2

D1-D2

C2

B4
B6

M3

I1

B8

BX
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ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)

F1A
F2A

F5A F7A
F3A
F4A F6A F8A

F7B

C3

S6

F1B

F6B

F4B

F2B
F3B

F5B

I3-S12
S9-I2
I6-S15
I5-S14
I7-S17
S11
I4-S13

C1

G2

S8

S10
S3
S4

S7
S2
S5
S1

S16

C5
S301505

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ELECTRICAL SYSTEM
WIRING DIAGRAM
A
AA
AS
B
B1
B2
B3
B4
B5
B6
B7
B8
BX
C1
C2
C3
C4
C5
C6
D1
D2
EV1
EV2
EV3
F1A
F2A
F3A
F4A

F5A
F6A
F7A
F8A
F1B
F2B
F3B
F4B
F5B
F6B
F7B
G1
G2
I1
I2
I3
I4
I5
I6
I7

Alternator
Horn
Cigarette lighter
12 V battery
Engine coolant temperature bulb
Engine oil bulb
Engine coolant warning light bulb
Parking brake microswitch
Lifted hopper microswitch
Brake light microswitch
Hydraulic system oil cooler fan bulb
Reverse gear sensor
Engine start safety sensor
Ignition switch
Combination switch
Warning buzzer/parking brake buzzer
Reverse gear buzzer
Hour counter/revolution counter/water temperature indicator
Climate control system compressor
Diode
Diode
Fuel solenoid valve
Skirt solenoid valve
Skirt solenoid valve
Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)
Fuel solenoid valve fuse (10 A)
Cab blower/flashing light/windscreen wiper fuse (15 A)
Dust control system water pump fuse (10 A)
Dust control system water pump/climate control system
(optional) fuse (20 A)
Reverse gear buzzer fuse (10 A)
Warning lights/glow plug control unit fuse (10 A)
Electric jack warning light fuse (10 A)
Hopper lid opening/closing electric jack fuse (15 A)
Hazard warning light fuse (10 A)
Brake light/horn fuse (10 A)
Left side running light fuse (10 A)
Right side running light fuse (10 A)
Low beam fuse (15 A)
High beam fuse (15 A)
Cigarette lighter fuse (20 A)
Dust control system water level indicator
Fuel level indicator
Skirt lifting switch
Hazard warning light switch
Windscreen wiper/washer switch
Water pump switch
Cab blower switch
Climate control system switch (2 speed/1 speed)
Electric jack switch

L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
L11
L12
L13
L14
L15
L16
M1
M2
M3
M4
M5
M6
M7
M8
P
R1
R2
R3
R4
R5
R6
R7
RS
RX
RY
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
S17
TM
K

(*)

RS 501

Left front turn signal
Right rear turn signal
Right front turn signal
Left rear turn signal
Left brake light
Right brake light
Left front running light
Right rear running light
Right front running light
Left rear running light
Left low beam
Right low beam
Left high beam
Right high beam
Flashing light
Licence plate light
Starter
Hydraulic system oil cooler fan motor
Windscreen wiper motor
Dust control system water pump (normal)
Cab blower motor
Climate control system blower motor
Windscreen washer motor with tank
Hopper lid opening/closing electric jack motor
Climate control system pressure switch
Engine glow plug control unit relay
General relay
Reverse gear buzzer relay
Turn signal intermittence relay
Water pump relay
Climate control system compressor relay (*)
Climate control system condenser fan relay (*)
Cab blower resistance
Engine start safety relay
Engine start safety relay
Glow plug warning light
Battery warning light
Engine oil warning light
Engine coolant warning light
Parking brake warning light
Lifted hopper warning light
Running light indicator light
High beam indicator light
Hazard warning light indicator
Turn signal indicator light
Dust control system low water warning light
Windscreen wiper warning light
Dust control system water pump warning light
Blower warning light
Climate control system warning light
Low fuel warning light
Hopper lid opening/closing electric jack warning light
Climate control system thermostat
Glow plugs

Optional for some countries.

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ENGLISH

ELECTRICAL SYSTEM
WIRING DIAGRAM (Continues)

(*)

4.0

31

30

15
15/54

2.0

(*)

Color code

85

BK

87a

C5

B5
B3
B2

PK-WH

LIGHT BU-WH

S6
S4
S3

BK

S16

G2

GY-RD

OG-GN

S2

LIGHT PK

A

PK-YE

Black
Blue
Brown
Green
Grey
Orange
Pink
Red
Violet
White
Yellow
Light blue
Light pink

BK

C3

B4

S5

GY-GN

C4

30
RD-BK

R3

OG-GN

B8

PK-WH

F5A

86

BK
BN-BK

BK
BU
BN
GN
GY
OG
PK
RD
VT
WH
YE
LIGHT BU
LIGHT PK

F7A

RD

Bx

F2A

BK
PK-WH

VT-RD

GY-RD

VT-RD

30
85

GY-RD

87

BN-BK

R2

BK

86

RD
BN
BK

EV1

PK-BK

S1

VT-RD
PK-WH

30

B1
86

85
87a

Ry

30

85
87a

86

R1

Rx

30

T
85

50

L

BU-BK

RD

C1

0 1 2

BK
BU-BK

M1

BN-BK
15/54

K

87

BK

30

86

50

GY-RD

F6A

RD
RD
RD

B

-

+

BK

S301506

(*)

Continues to the next page

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(*)

(*)

31

S17

PK-YE

PK-YE

I7

BK

BU-BK

PK-BK

M8

EV2

I1

I 0 II

EV3

WH-GN

B7

F1A

YE-GN

M2

YE-RD

F8A

1

BK

4

2

L1

0

F1B

OG-RD
LIGHT BU

BU

BN-BK

BU-WH

3

OG

1 0 2

1/3 C2

R4

6

8

L2

5

OG

30

BU

RS 501
L3

1

L4

S10

BU

WH

I2

S9

10

BK

BU

BK

BK

7

L5

RD

F2B

L6

RD

B6

YE-RD

AA

1/3 C2

1 C

BU

L7

YE-RD
GY-YE

L8

F3B

S7

GY-YE

YE

0 1 2 3

BN-BK
YE

Continues from the previous page
L9

GY-YE

YE

GY-YE

L10

F4B

1/3 C2

GY-YE

(*)

15
15/54

L16

YE-RD

VT

31

15

30

(**)

(**)

4.2

2.2

(**)

SERVICE MANUAL

33015500(3)2008-02

ENGLISH

ELECTRICAL SYSTEM

WIRING DIAGRAM (Continues)

S301506

(**) Continues to the next page

135

BU
BK

BU

LIGHT BU

OG

WH-RD

WH-YE

4.3

2.3

(**)

(**)

F5B

31

L11

GY-BK

GY-YE

L12
L13

VT

S8

VT-BK

F6B

L14

VT

I3

II I 0

M7

WH-RD

10

9

5

4 2 7

M3

BU-RD

RD

L15

S12

BU-RD

G1

I4

R5

I 0

5

WH-RD
85

86

WH-YE

BK

WH-BU

87

3

F4A

BK

S13

87a

30

WH

S11

WH-RD

15

M4

WH

30

PK

RS 501
VT-BK

I5

2

1
0

BU-BK

M5

OG

(**)

D2

D1

F3A

RS

GN-WH
GY-BK

S14

I6

0 I 2

2

3

R6

85

86

5

C6

85
87

R7

86

WH-RD

GY-RD

TM

P

6

30

1

BK

WH-RD

BN

33015500(3)2008-02
BK

(**) Continues from the previous page
BK

S15

M6

87

30

WH-RD

136
YE-GN

F7B

AS

ENGLISH
SERVICE MANUAL

ELECTRICAL SYSTEM

WIRING DIAGRAM (Continues)

S301506

WH

WH-BU

BK

GY

SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM
TROUBLESHOOTING
See the previous chapters related to the use of the electrical system.
Other possible causes:
1. The fuses are burnt (replace).
2. The harness is cut or pressed (repair).

RS 501

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ENGLISH

SERVICE MANUAL

ELECTRICAL SYSTEM
BATTERY FLUID LEVEL CHECK
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing battery check and cleaning procedures.
1.
2.
3.
4.
5.
6.
7.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the left panel (23) in the cab.
Check the electrolyte level in the battery (A) and, if necessary, top up.
If necessary, clean the battery.
Check the battery terminal connections for oxidation.
Install the left panel (23) in the cab and the screws.

A
S301507

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ENGLISH

ELECTRICAL SYSTEM
FUSE REPLACEMENT
1.
2.
3.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Operating on the cab dashboard, remove the transparent cover of the fuse box (A) or (B) and replace the suspected fuse
among the following:
Fuse box B
A) Hazard warning light fuse (10 A)
B) Brake light/horn fuse (10 A)
C) Left side running light fuse (10 A)
D) Right side running light fuse (10 A)
E) Low beam fuse (15 A)
F) High beam fuse (15 A)
G) Cigarette lighter fuse (20 A)
H) Free fuse holder
Fuse box A
I)
Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)
J) Fuel solenoid valve fuse (10 A)
K) Cab blower/flashing light/windscreen wiper fuse (15 A)
L) Dust control system water pump fuse (10 A)
Dust control system water pump/climate control system (optional) fuse (20 A)
M) Reverse gear buzzer fuse (10 A)
N) Warning lights/glow plug control unit fuse (10 A)
O) Electric jack warning light fuse (10 A)
P) Hopper lid opening/closing electric jack fuse (15 A)

4.

Install the transparent cover of the fuse box (A) or (B).

i

j

k

l

m n o

p

A

B
a

b c d e f gh

A

B

S301429

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SERVICE MANUAL

ELECTRICAL SYSTEM
RELAY REPLACEMENT
1.
2.
3.
4.

5.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws (C) and lower the dashboard panel (D) in the cab.
Remove the suspected relay among the following:
• General relay (R2)
• Water pump relay (R5)
• Reverse gear buzzer relay (R3)
• Turn signal intermittence relay (R4)
• Climate control system compressor relay (R6) (optional)
• Condenser fan relay (R7) (optional)
• Engine glow plug control unit relay (R1)
• Engine start safety relay (RX)
• Engine start safety relay (RY)
Assemble the components in the reverse order of disassembly.

C
D
C

R1

RY RX R7

R6

R4 R3

R5 R2

S301508

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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM
CONTROL PANEL DISPLAY REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.

Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the left panel (23) in the cab.
Disconnect the negative pin from the battery (A).
Remove the screws (C) and lower the dashboard panel (D) in the cab.
Remove the screws (E) and lower the display (F).
Disconnect the connectors (G) and (H), then recover the display (F).
Install the new display by performing steps 6 and 7 in the reverse order.
Adjust the display by using the keyboard of tool no. 33014099 connected to connectors (I) and (J).

D

C

C

A

E

J

G

F

I

H
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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM
LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT
Preliminary operations
1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
2. Turn the ignition key (76) to OFF position and remove it.
Bulb replacement
3. Remove the screws (A) and move the headlight (B).
4. Replace the burned bulbs.
5. Install the headlight (B) and fasten it with the screws (A).
6. Adjust the headlights according to the following procedure.
Low beam adjustment
7. Use the screws (C) and (D), in the following way:
• To adjust the beam vertically, turn the screws (C) and (D) simultaneously;
• To adjust the beam horizontally, turn the screws (C) and (D) individually.

D

A
C

A

B
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