Nilfisk Advance America Rs 501 Users Manual 33015499(3)2008 02
RS 501 to the manual d0633289-66f2-4726-ba4a-ab6f04b5ab30
2015-02-05
: Nilfisk-Advance-America Nilfisk-Advance-America-Rs-501-Users-Manual-495188 nilfisk-advance-america-rs-501-users-manual-495188 nilfisk-advance-america pdf
Open the PDF directly: View PDF 
.
Page Count: 146 [warning: Documents this large are best viewed by clicking the View PDF Link!]
RS 501
ENGLISH SERVICE MANUAL
33015499(3)2008-02
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 1
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
ENGLISH SERVICE MANUAL
233015500(3)2008-02 RS 501
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
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 3
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 Nilfi sk Literature Service Department:
RS 501 Spare Parts List – Nilfi sk Form Number 33015502
RS 501 User Manual – Nilfi sk Form Number 33015501
SAFETY
The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary
precautions to safeguard people and property.
DANGER!
It indicates a dangerous situation with risk of death for the operator.
WARNING!
It indicates a potential risk of injury for people or damage to objects.
CAUTION!
It indicates a caution related to important or useful functions.
Pay careful attention to the paragraphs marked by this symbol.
NOTE
It indicates a remark related to important or useful functions.
CONSULTATION
It indicates that it is necessary to consult the User Manual before performing any procedure.
–
–
ENGLISH SERVICE MANUAL
433015500(3)2008-02 RS 501
GENERAL INFORMATION
GENERAL SAFETY INSTRUCTIONS
Specifi c warnings and cautions to inform about potential damages to people and machine are shown below.
DANGER!
This machine must be used by properly trained and authorised personnel only.
Moreover, the operator must:
Be of full age
Have a driving license
Be in normal psycho-physical conditions
Not be under the effect of substances that alters the nervous system (alcohol, psycopharmaceuticals,
drugs, etc.)
Before performing any maintenance/repair procedure remove the ignition key, engage the parking brake
and disconnect the battery.
Do not wear jewels when working near electrical components.
Do not work under the lifted machine without supporting it with safety stands.
When working under open hoods/lids, make sure that they cannot be closed by accident.
When performing maintenance procedures with the lifted hopper, apply the relevant support rods.
Do not operate the machine near toxic, dangerous, fl ammable and/or explosive powders, liquids or vapors.
Be careful, fuel is highly fl ammable.
Do not smoke or bring naked fl ames in the area where the machine is refuelled or where the fuel is stored.
Refuel outdoors or in a well-ventilated area, with the engine off.
Do not fi ll the fuel tank to the top, but leave at least 4 cm from the fi ller neck to allow the fuel to expand.
After refuelling, check that the fi ller cap is tightly closed.
If any fuel is spilled while refuelling, clean up the affected area and allow the vapors to dissipate before
starting the engine.
Avoid contact with skin and do not breathe in fuel vapors. Keep out of reach of children.
Do not tilt the engine too much to avoid fuel spillage.
During machine transportation, the fuel tank must not be full.
–
–
•
•
•
•
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
WARNING!
Carbon monoxide (CO) can cause brain damage or death.
The internal combustion engine of this machine can emit carbon monoxide.
Do not inhale exhaust gas fumes.
Only use indoors when adequate ventilation is provided, and when an assistant has been instructed to look
after you.
Do not lay any object on the engine.
Before working on the engine turn it off. To prevent the engine from starting accidentally, disconnect the
battery negative terminal.
See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this
Manual.
–
–
–
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 5
GENERAL INFORMATION
WARNING!
Carefully read all the instructions before performing any maintenance/repair procedure.
Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by the machine
moving parts.
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using
compressed air or water gun.
Avoid contact with battery acid, do not touch hot parts.
Do not leave the machine unattended with the ignition key inserted and the parking brake deactivated.
Do not remove or modify the plates affi xed to the machine.
To drive on public roads, the machine must follow local licensing requirements.
The machine has been designed to be used as a sweeper, do not use it for different purposes.
In case of part replacement, order ORIGINAL spare parts from an authorised Dealer or Retailer.
The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries,
etc.), which are subject to standards that require disposal in special centres (see the Scrapping chapter).
While the engine is running the silencer heats up. Do not touch the silencer to avoid serious scalding or
fi re.
Do not run the engine if the oil level is low, to avoid damaging it seriously. Check the oil level with the
engine off and the machine on a level surface.
Do not run the engine if the air fi lter is not installed, to avoid damaging it.
The coolant line is pressurised; do not perform any check until the engine has cooled down and, even if the
engine is cold, the tank plug must be opened with extreme care.
Only use original spare parts or parts of matching quality for the diesel engine. Using spare parts of lower
quality can seriously damage the engine.
See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this
Manual.
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
ENGLISH SERVICE MANUAL
633015500(3)2008-02 RS 501
GENERAL INFORMATION
TECHNICAL DATA
Dimensions and weights Values
Machine length (broom bristles not included) 3,065 mm
Machine width (broom bristles not included) 1,315 mm
Distance between front and rear wheels 1,475 mm
Front wheel base 930 mm
Rear wheel base 840 mm
Machine height 1,997 mm
Minimum distance from the ground (skirts not included) 90 mm
Maximum front working angle 18°
Maximum dumping height 1,460 mm
Front tires R165/70 R14C 89R
Rear tires R165/70 R14C 89R
Tire pressure 3.75 Bar
Standard side broom diameter 720 mm
Optional side broom diameter 650 mm
Total machine weight, in running condition (without operator) 1,500 Kg
Performance data Values
Maximum forward speed (for transport only) 20 km/h
Maximum working speed 12 km/h
Maximum reverse speed 8 km/h
Gradeability at full load 22% (30% optional)
Minimum inner turning radius 2.46 m
Maximum side broom speed 80 rpm
Collection system Suction
Cleaning width 1,600 mm
Filtering system Metallic net
Sound pressure level at workstation (ISO/EN 3744) at maximum working speed 82 dB(A)
Certifi ed sound power (2000/14/EC) at maximum working speed 108 dB(A)
Measured sound power (ISO/EN 3744) at maximum working speed 106 dB(A)
Hopper capacity 500 liters
Hopper maximum load 380 Kg
Dust control By water
Dust control system tank total capacity (No. 2) 240 liters
Lighting and signalling system Road type
Transmission Hydrostatic servoassisted
Steering system On the rear axle, power assisted
Brake Hydraulic
Parking brake Mechanic
Controls Hydraulic
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 7
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
ENGLISH SERVICE MANUAL
833015500(3)2008-02 RS 501
GENERAL INFORMATION
Hydraulic system data Values
Maximum drive system pressure 250 Bar
Maximum accessory system pressure 120/200 Bar
Hydraulic system oil type (at ambient temperature above 10°C) AGIP Arnica 46 (****)
NOTE
If the machine is to be used at ambient temperatures below 10°C, the oil should be replaced with equivalent oil having a
viscosity of 32 cSt. For temperatures below 0°C, use oil with lower viscosity.
(****) See the below hydraulic system oil technical data and reference data tables.
TECHNICAL DATA REFERENCE DATA
AGIP ARNICA 46 32 ISO-L-HV
Viscosity at 40°C mm2/s 45 32 ISO 11158
Viscosity at 100°C mm2/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.
–
–
–
–
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 9
GENERAL INFORMATION
MAINTENANCE
The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.
WARNING!
See GENERAL INFORMATION and SAFETY paragraphs.
The following table provides the scheduled maintenance. The intervals shown may vary according to particular working conditions,
which are to be defi ned by the person in charge of the maintenance.
The instructions relating to the maintenance procedures given in the following table are described in the next paragraphs.
SCHEDULED MAINTENANCE TABLE
Maintenance
Running-in
period (after the
fi rst 50 hours)
Every 10
hours or
before use
Every
200
hours
Every
600
hours
Every
1,200
hours
Every
2,400
hours
Long
periods
Engine oil level check
Engine air fi lter cleaning
Engine radiator fi n cleaning check
Engine coolant level check
Battery fl uid level check
Hydraulic system oil level and drain fi lter effi ciency
check
Hydraulic system oil cooler fi n check and cleaning
Hopper, fi lter and suction hose cleaning, and
gasket check
Dust control system nozzle and fi lter cleaning
Brake fl uid level check
Reverse gear buzzer operation check
Diesel engine start-up safety system check
Tire pressure check
Suction inlet and skirt height and operation check
Side broom position check and adjustment
Engine oil change (7)(8)
Dust control system water fi lter cleaning
Parking brake check
Alternator belt tension check (7)
Climate control system compressor belt tension
check
Diesel engine oil fi lter replacement (7)(8)
Fuel fi lter replacement (7)
Nut and screw tightening and leakage check
ENGLISH SERVICE MANUAL
10 33015500(3)2008-02 RS 501
GENERAL INFORMATION
Maintenance
Running-in
period (after the
fi rst 50 hours)
Every 10
hours or
before use
Every
200
hours
Every
600
hours
Every
1,200
hours
Every
2,400
hours
Long
periods
Lubrication
Engine coolant line sleeve check (7)
Drive system pump oil fi lter check
Hydraulic system oil drain fi lter replacement
Hydraulic system oil suction fi lter replacement
Alternator belt replacement (3)
Cab air fi lter replacement (1)
Injector calibration and cleaning (2) (3)
Climate control system belt replacement
Engine coolant change (3)
Hydraulic system oil change (3)
Brake system check
Hydraulic system pump pressure check
Minor engine overhaul (2) (4)
Major engine overhaul (2) (5)
(1) Or every 6 months
(2) Maintenance to be performed by Lombardini authorised Service Center
(3) Or every two years
(4) After 5,000 hours
(5) After 10,000 hours
(7) Every year, if the machine is not frequently used
(8) If a lower-quality oil is used, change it every 125 hours
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 11
GENERAL INFORMATION
MACHINE NOMENCLATURE
Throughout this Manual you will fi nd numbers in brackets, for example: (2). These numbers refer to the components indicated in
these two nomenclature pages. Refer to these pages whenever it will be necessary to identify a component mentioned in the text.
Cab
Left door
Hopper
Diesel engine
Suction fan
Flashing light
Dust control system left tank
Front fi xed 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 fi lter
Drain fi lter
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 fi lter
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 fi lter
Fuel tank fi ller neck
Hopper support rods
Left water tank fi ller plug
Right water tank fi ller plug
Brake fl uid tank
Windscreen wiper fl uid 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
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.
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)
Fuse box B
Fuse box A
Indicators and warning lights
Optional indicator light
Optional indicator light
Engine coolant temperature
High beam indicator light
Running light indicator light
Charged battery indicator light (together with the indicator
light a buzzer activates with intermittent sound)
Parking brake indicator light (together with the indicator
light a buzzer activates with continuous sound)
Glow plug pre-heating warning light
Hour counter/revolution counter display:
It displays the hours, when the ignition key (76) is
turned on the fi rst position, before running the engine;
It displays the engine speed, when the engine is
running and the charged battery warning light is off.
Low fuel warning light (a buzzer activates together with the
warning light)
Optional indicator light
Engine coolant high temperature warning light (a buzzer
activates together with the warning light)
Engine oil pressure warning light (a buzzer activates
together with the warning light)
Turn signal indicator light
Hopper lid opening/closing switch
Rear bumper
Diesel engine serial number/technical data plate (another
plate showing the same data as the plate affi xed on the
diesel engine)(*)
High-pressure washing system hose with reel (*)
High-pressure water quick coupling (*)
Breather fi lter hood fasteners
Rear suction pipe fastener
Front skirt
Machine serial number
Hopper (dumping position)
Suction hose gasket
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
•
•
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
ENGLISH SERVICE MANUAL
12 33015500(3)2008-02 RS 501
GENERAL INFORMATION
Hopper manual lifting hand pump lever
High-pressure water gun
Serial number plate/technical data/certifi cation marking
Right water tank drain plug
Left water tank drain plug
High-pressure washing system pressure gauge
Breather fi lter hood
Hydraulic system oil fi ller plug
Hydraulic system pressure intake (on drive system pump)
Hydraulic system pressure intake (at suction fan pump)
Hydraulic system pressure intake (at accessory and
steering system pump)
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
Hopper lid suction sealing gasket
Document holder
Hopper lifting/lowering lever safety fl ange
Suction inlet and broom lifting/lowering lever safety fl ange
Driver’s seat forward/backward adjustment lever
Ashtray
High-pressure water gun sprinkler nozzle
Cigarette lighter
Can holder
Broom speed adjuster (***)
Hydraulic system oil level indicator
(*) Optional for some countries.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 13
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
99
100
19
18
7
8
2
11
10
1
103
104 45
17
102
26
9
15
9
16
8
21
24
20
13
6
3101113
25
97
98
110
112
111
115
12
14
4
S301479
ENGLISH SERVICE MANUAL
14 33015500(3)2008-02 RS 501
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
32
27 31
118
105
48
28
29 30
26
40
46 47
37
41 49 42
39
38
33
107
51
43
35
50
44
36
106
5
114
128
S301617
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 15
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
123
120
121
66
61
59
65
69
63
122 56
53
55
68
108 58
62
67
57
54
60
64
109
23
34
124
125
126
119
52
22
127
116
117
S301481
ENGLISH SERVICE MANUAL
16 33015500(3)2008-02 RS 501
GENERAL INFORMATION
MACHINE NOMENCLATURE (Continues)
80
79
81 77 71 73 74 72 96 76
70
1
78
85
86
87
88
89
82 83 84
90
95
94
93
92
91
75
S301407
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 17
SWEEPING SYSTEM
SWEEPING SYSTEM
DESCRIPTION
The sweeping system consists of:
Right side broom
Left broom
Broom arms
The brooms (A) and (B) are supported by arms (C) which are fastened to the machine frame.
Broom rotation is activated by hydraulic motors.
For proper sweeping and conveyance of dust and debris towards the suction inlet:
Broom height and tilting must be properly adjusted;
Proper brooms must be used according to the type of ground to be cleaned. The following types are available:
Polypropylene brooms
Polypropylene and steel brooms
AB
C
C
S300857
A)
B)
C)
–
–
•
•
ENGLISH SERVICE MANUAL
18 33015500(3)2008-02 RS 501
SWEEPING SYSTEM
TROUBLESHOOTING
The brooms do not clean correctly
Possible causes:
The brooms are not adjusted correctly (adjust).
The broom speed is not correct (adjust).
The brooms do not rotate
Possible causes:
There are oil leaks from the hydraulic system hoses (replace the hoses).
The hydraulic motors are faulty (replace).
The accessory system hydraulic pump does not pressurize the oil in the circuit (check the hydraulic system oil pressure).
1.
2.
1.
2.
3.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 19
SWEEPING SYSTEM
SIDE BROOM POSITION CHECK AND ADJUSTMENT
NOTE
Brooms of various hardness are available. This procedure is applicable to all types of brooms.
Check
Check the side brooms for proper height and tilting, according to the following procedure:
Drive the machine on a level ground.
While keeping the machine stationary, fully lower the side brooms and allow them to rotate for a few seconds.
Stop and lift the side brooms, then move the machine.
Check that the size and orientation of the prints left by the side brooms are as follows:
The right side broom must touch the ground along a circle arc (A) ranging from “11 o’clock” position to “4 o’clock” position.
The left side broom must touch the ground along a circle arc (B) ranging from “8 o’clock” position to “1 o’clock” position.
Adjust the broom height when the prints are out of specifi cation, according to the following procedure.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Broom height adjustment
On both sides of the machine, operate on the tensioning self-locking nut (C) of the spring (D) and consider the following:
To lower the broom, the nut (C) must be unscrewed;
To lift the broom, the nut (C) must be screwed.
Perform step 1 again.
Broom forward tilting angle adjustment
On both sides of the machine, loosen the screws (E) and (F), then adjust the forward tilting angle (G).
When the adjustment is completed, tighten the screws (E) and (F).
Perform step 1 again.
Broom side tilting angle adjustment
On both sides of the machine, loosen the screws (I) and (L), then adjust the side tilting angle (H).
When the adjustment is completed, tighten the screws (I) and (L).
Perform step 1 again.
Broom side position adjustment
The purpose of this adjustment is to improve the side position of the brooms as to the suction inlet (12).
To perform the adjustment, loosen the nuts (J) and operate on the screw (K), thus changing the side position of the brooms.
When the side brooms are too worn out, the adjustment is not possible; replace the brooms according to the instructions in the
relevant paragraph.
1.
•
•
•
•
•
•
2.
3.
4.
•
•
5.
6.
7.
8.
9.
10.
11.
12.
ENGLISH SERVICE MANUAL
20 33015500(3)2008-02 RS 501
SWEEPING SYSTEM
SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues)
S301482
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 21
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.
Lift the brooms and engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the centre screw (A), then remove the broom (B) to be replaced. Recover the key.
Remove the screws (D), then remove the fl ange (E).
Install the fl ange (E) and secure it on the new broom with the screws (D).
Install the new broom (B) with the key, then tighten the centre screw (A).
Adjust the height of the new broom according to the procedure shown in the previous paragraph.
A
B
D
D
E
BB
S300859
1.
2.
3.
4.
5.
6.
7.
ENGLISH SERVICE MANUAL
22 33015500(3)2008-02 RS 501
SWEEPING SYSTEM
BROOM SPEED ADJUSTMENT
Speed measurement
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Connect a speed measurement indicator with a portable tachometer to the broom (10) or (11).
Start the machine and run the engine at maximum speed and set the broom speed adjuster (127) to maximum speed (as
shown in the User Manual). In this condition, measure the broom speed with the portable tachometer. Turn off the machine.
The broom speed must be: 80 rpm
If necessary, change the broom speed according to the following procedure.
Speed adjustment
Remove the screws and the right panel (22) in the cab.
To change the broom speed, loosen the locknut (A) and turn the screw (B), then tighten the locknut (A).
Perform step 4 again.
B
A
S301510
1.
2.
3.
4.
5.
6.
7.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 23
DUST AND DEBRIS COLLECTION SYSTEM
DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION
The dust and debris collection system consists of:
Suction fan
Dust and debris suction fi lter
Hopper
Suction hose
Suction inlet
Skirt
Gasket between suction inlet and hopper
Hopper lid
Hopper suction hole
Open lid support rod
Lifted hopper locking pins
Lifted hopper locking pins housing
Lifted hopper locking pins holes
Air breather fi lter
Hopper lid suction sealing gasket
The suction fan (A), activated by an hydraulic motor, creates vacuum inside the hopper (C). The vacuum determines the suction
capacity of the suction inlet (E) through the suction hose (D).
The hopper (C) is made of steel.
It is fastened with two pins to a mechanic/hydraulic lifting system (O) (for hopper lifting) and to a dumping system (P) (for hopper
tilting). The lid (H), which can be opened with an hydraulic control system, allows for debris discharging.
Both the lid (H) and the suction hole (I) are equipped with gaskets, which allow the suction inlet (E) to reach the maximum suction
capacity.
Inside the hopper there are two stainless steel fi lters having the following functions:
The suction fi lter (B) retains dust and debris during fan suction phase, and makes them settle in the hopper;
The breather fi lter (N) retains dust and debris escaped from the suction fi lter, and does not allow them to be discharged
externally.
Both fi lters can be easily removed and cleaned.
To perform checks and maintenance procedure safely with the hopper lifted and the lid opened, perform the following procedures:
Turn the rod (J) to lock the lid (H) in open position.
Remove the pins (K) from the housings (L) and place them into the holes (M) to lock the hopper (C) in lifted and dumped
position.
The suction inlet is made of sheet steel.
It is equipped with three wheels, which allow it to follow the pattern of the surface to be cleaned.
On its front side there is a skirt (F) that must be lifted to collect bulky debris.
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
N)
Q)
–
–
–
–
ENGLISH SERVICE MANUAL
24 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
DESCRIPTION (Continues)
D
G
E
F
C
B
N
A
H
J
K
P
K
L
M
K
I
O
Q
S301483
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 25
DUST AND DEBRIS COLLECTION SYSTEM
TROUBLESHOOTING
The suction fan turns but it is not effi cient
Possible causes:
The fi lters are clogged (clean).
The suction hose is clogged (clean).
The suction hose is cut/torn (replace).
The gasket between the suction inlet and the hopper is broken or misadjusted (replace or adjust).
The hopper lid gasket is broken (replace).
There is no pressure at the suction fan motor drive pump (adjust the pump pressure).
The suction fan does not turn
Possible causes:
The motor is faulty (replace).
The control valve assembly is stuck (repair).
The pump is faulty (replace).
The suction inlet does not collect debris effi ciently
Possible causes:
The suction inlet position is incorrect (check the suction inlet and skirt height and effi ciency).
The skirt opening force is not suffi cient
Possible causes:
The skirt opening pressure is incorrect (adjust).
The hopper does not lift/lower
Possible causes:
The control valve assembly is stuck (repair).
The cylinder gaskets are worn (repair the cylinder).
The rear lid does not open/close
Possible causes:
There is no voltage in the actuator (repair the electrical system).
The actuator is faulty (repair/adjust the actuator cams).
1.
2.
3.
4.
5.
6.
1.
2.
3.
1.
1.
1.
2.
1.
2.
ENGLISH SERVICE MANUAL
26 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed
air or water gun.
Preliminary operations
Empty the hopper (3), drive the machine to a cleaning/washing appointed area, then engage the parking brake with the lever
(66).
Lift and dump the hopper (3), according to the procedure shown in the User Manual.
Install the lid support rod (27).
Hopper cleaning
Clean the hopper (H) with pressurised water from a hydrocleaner (G).
Carefully check the suction sealing gasket (U) for integrity, and replace it if necessary.
Suction hose cleaning
Thoroughly clean the suction hose (R) inside, up to the suction inlet, with pressurised water.
Carefully check the suction sealing gasket (V) for integrity, and replace it if necessary.
Suction fi lter cleaning
Inside the hopper, remove the suction fi lter fastener (A).
Remove the suction fi lter (B).
Wash the defl ector (C) and the fan (D) with pressurised water; check that all fan sectors (T) are clean.
Clean the suction fi lter (F) with pressurised water from a hydrocleaner (E).
Install the suction fi lter (B) and secure it with the fastener (A).
Remove the lid support rod (27) and lower the hopper (3) according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Breather fi lter cleaning
With a ladder and the help of an assistant, disengage the fasteners (I) of the breather fi lter hood (J).
Open the hood (K) and install the safety pin (L).
Remove the mounting screws (M), then remove the breather fi lter (N).
Clean the breather fi lter (P) with pressurised water from a hydrocleaner (O).
Install the breather fi lter and its hood performing steps from 15 to 17 in reverse order.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 27
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)
A
E
F
DCB
UHG
K
L
J
I
D
T
S300862
ENGLISH SERVICE MANUAL
28 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)
NMPO
V
R
S300863
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 29
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK
Preliminary operations
Engage the parking brake with the lever (66).
Lift the suction inlet (12), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Suction inlet wheel check
Check that the three wheels (A) of the suction inlet are in good conditions and turn freely (they must not be bent/misshapen
because of bumps or excessive pressure, etc.). Check also that the rubber thickness (B) is not lower than some millimeters.
If necessary replace the wheels (A) (see the procedure in relevant paragraph).
Sliding panel check
Check that the main sliding panel (C) and the front (D) and (E) and rear (H) sliding panels are in good conditions and that their
thickness (F) is not lower than 5 mm, otherwise replace them (see the procedure in the relevant paragraph).
It is important to replace the sliding panels (C), (D), (E), and (H) when they are not completely worn, to avoid damaging the
relevant mounting screws and making them diffi cult to remove.
Replace the sliding panels (C), (D), (E), and (H) as a unit, to avoid steps in the union areas (G), caused by different levels of
wear.
Suction inlet skirt and wheel adjustment check
Check that the skirt (I) is integral and that it does not have excessive tears (J) or lacerations (K), which can affect the suction
inlet operation.
If necessary replace the skirt (I) (see the procedure in the relevant paragraph).
Drive the machine on a level ground and lower the suction inlet (12) according to the procedure shown in the User manual.
Turn the ignition key (76) to OFF position and remove it.
Check that the distance (L) of the skirt from the ground is not bigger than 1 cm. Greater distances can affect the suction inlet
operation.
If necessary replace the skirt (K) (see the procedure in the relevant paragraph).
Also check that, when the three wheels (A) contact the ground, the sliding panels (C), (D), (E), and (H) do not touch the
ground, otherwise the wheels (A) must be replaced to avoid an excessive wear of the sliding panels (for wheel replacement
procedure, see the relevant paragraph).
Start the machine according to the procedure shown in the User Manual, then press the switch (69) and check that the skirt
(I) lifts freely. Check that it lifts also when a force of some kg is applied (simulating to move bottles or other heavy objects that
must then be collected). If necessary, adjust the opening force of the skirt (I) according to the following procedure:
Turn off the machine.
Remove the screws and the right panel (22) in the cab.
Loosen the control valve locknut (N) and turn the screw (O) as necessary, reminding that:
The opening force decreases by loosening the screw;
The opening force increases by tightening the screw.
When the adjustment is completed, tighten the locknut (N).
Install the right panel (22) in the cab and tighten the screws.
Reset
Assemble the components in the reverse order of disassembly.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
•
•
•
–
–
•
•
12.
ENGLISH SERVICE MANUAL
30 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK (Continues)
B
H
A
D
G
C
E
FG
A
A
L
IK
J
F
G
O
N
S301484
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 31
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY
NOTE
To remove the rear wheel (C), the machine must be lifted with an appropriate hoisting system. Otherwise, remove the
suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following disassembling
procedures.
Front wheels (A) and (B) removal/installation
Engage the parking brake with the lever (66).
Lift the suction inlet (12), according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
On both sides of the machine, loosen the screws (E) and (F), then remove the front wheels (A) and (B).
Install the new front wheels (A) and (B) and fasten them with the screws (E) and (F).
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
Front wheels (A) and (B), and rear wheel (C) removal/installation
Place the machine on the appropriate hoisting system (if present) and lift it.
If the hoisting system is not available, remove the suction inlet assembly (D) (see the procedure in the relevant paragraph).
Remove the screws (E), (F) and (G), then remove the wheels (A), (B) and (C).
Install the new wheels (A), (B) and (C) and fasten them with the screws (E), (F) and (G).
Perform step 1 again.
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
G
AD
B
C
F
E
S301485
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
32 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY
NOTE
To remove the suction inlet sliding panels, the machine must be lifted with an appropriate hoisting system. Otherwise,
remove the suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following
disassembling procedures.
Place the machine on the appropriate hoisting system (if present) and lift it.
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).
FEDBF
A
C
C
A
F
S301486
1.
2.
3.
4.
5.
6.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 33
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION INLET DISASSEMBLY/ASSEMBLY
Disassembly
Remove the side brooms (see the procedure in the relevant paragraph).
Lower the suction inlet (12), according to the procedure shown in the User Manual.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Disconnect the hydraulic system hoses (A) and (B) from the suction inlet (C) and plug them.
Disconnect the dust control system water hose (D).
Remove the nuts (E) and pins (F).
Move the suction inlet (C) forward, and loosen the suction hose clamp (G).
Disconnect the suction hose (H) from the suction inlet.
Remove the suction inlet (C).
Assembly
Assemble the components in the reverse order of disassembly.
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
A
BH
G
F
C
E
F
D
E
S301487
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
34 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
SKIRT REPLACEMENT
Lower the suction inlet (12), according to the procedure shown in the User Manual.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the clip (A) and the skirt (B).
Remove the screws (C), then remove the skirt (D).
Install the new skirt (D) and fasten it with the screws (C).
Install the skirt (B) and the clip (A).
Lift the suction inlet (12), according to the procedure shown in the User Manual.
B
C
D
A
S300868
1.
2.
3.
4.
5.
6.
7.
8.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 35
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER POSITION ADJUSTMENT
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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 profi les (D) match the frame
profi les (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.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
ENGLISH SERVICE MANUAL
36 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER POSITION ADJUSTMENT (Continues)
F
G
I
H
J
L
D
C
B
A
D
C
B
A
E
E
S300869
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 37
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER LID CLOSING ACTUATOR ADJUSTMENT
Preliminary operations
Empty the hopper (3), according to the procedure shown in the User Manual.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
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).
Remove the screws (A), then remove the cover (B) and the gasket (C) of the actuator (R), under the rear side of the hopper.
Lid safety hook closing
According to the procedure shown in the User Manual, turn the safety hook (D) of the lid (E) to closing position (as shown
in the fi gure); in this condition, loosen the security dowel (F) of the cam (G), and then turn the cam until the microswitch (H)
activates.
Open safety hook warning light adjustment
When the safety hook (D) of the lid (E) is turned to closing position (as shown in the fi gure), loosen the security dowel (I) of the
cam (J), and turn the cam until the corner (K) causes the microswitch (L) to activate and the warning light to turn off.
Lid safety hook opening end-of-stroke adjustment
According to the procedure shown in the User Manual, turn the safety hook (D) of the lid (E) to the opening end-of-stroke; in
this condition, loosen the security dowel of the cam (N), and then turn the cam until the microswitch (O) activates.
NOTE
To maximize cam adjustment consider the following:
The cam turns in the direction shown by the arrow (P) when the hook (D) opens;
The cam turns in the direction shown by the arrow (Q) when the hook (D) closes.
–
–
To check the cam proper adjustment, open and close the hook (D) several times.
Reset
Perform steps 3 to 7 in the reverse order.
BCR
A
S300964
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
ENGLISH SERVICE MANUAL
38 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
HOPPER LID CLOSING ACTUATOR ADJUSTMENT (Continues)
F
P
Q
G
I
NH LODE
K
J
S300965
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 39
DUST AND DEBRIS COLLECTION SYSTEM
MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY
Disassembly
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
With a ladder and the help of an assistant, disengage the fasteners (A) of the breather fi lter hood (B).
Open the hood (C) and install the safety pin (D).
Remove the mounting screws (E), then remove the breather fi lter (F).
Disconnect the hoses joints (G) and (H) from the suction fan motor (I).
Remove the mounting nuts (J) of the fl ange (M).
With an appropriate hoisting system, remove the suction fan motor assembly (K) by removing the silicone along the perimeter
(L) of the fl ange (M), then sling the assembly (K) by placing a rope around the motor (I) and the fi ttings (N).
At the workbench, remove the screw (O) and the fan (P).
Remove the nuts (Q) from the screws (R).
Remove the motor (I) from the fl ange (M).
Assembly
Assemble the components in the reverse order of disassembly and note the following:
Remove the silicone along the perimeter (L) of the fl ange (M) and from the fl ange housing on the hopper.
Apply new silicone along the perimeter (L) of the fl ange (M).
BACD
EF
S300870
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
•
•
ENGLISH SERVICE MANUAL
40 33015500(3)2008-02 RS 501
DUST AND DEBRIS COLLECTION SYSTEM
MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues)
O
P
R
M
J
N
G
N
H
Q
L
K
S301488
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 41
DUST AND DEBRIS COLLECTION SYSTEM
SUCTION HOSE DISASSEMBLY/ASSEMBLY
Preliminary operations
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
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).
Disassembly
Loosen the clamp (A) and disconnect the suction hose (B) from the suction inlet (C).
Loosen the left and right side mounting screws (D) of the suction hose upper end (E).
Remove the suction hose (F) by pulling it upwards.
Assembly
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
C
A
D
F
E
D
D
S300874
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
•
ENGLISH SERVICE MANUAL
42 33016312(0)2007-04 RS 501 UK
DUST AND DEBRIS COLLECTION SYSTEM
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 43
DUST CONTROL SYSTEM
DUST CONTROL SYSTEM
DESCRIPTION
The dust control system consists of:
Right water tank
Left water tank
Tank fi ller plugs
Broom nozzles
Suction inlet nozzles
Water fi lter
Hose
Water level indicator
Nozzle pump
Taps
Rear suction pipe nozzle
Opening tap
Tank drain plugs
The water gun connected to the dust control system consists of:
Water gun pump
Quick coupling
Water gun
Hose
Reel
Pressure gauge
C
I
J
D
DE
C
H
M
K
BA
G
F
IJE
E
DD
J
N
O
P
QR
O
P
S
M
B
L
FN
A
J
K
S301489
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
N)
O)
P)
Q)
R)
S)
ENGLISH SERVICE MANUAL
44 33015500(3)2008-02 RS 501
DUST CONTROL SYSTEM
TROUBLESHOOTING
No water from the nozzles
Possible causes:
The water fi lter is clogged (clean/replace).
The nozzles are clogged (clean).
No water to the nozzles
Possible causes:
The water pump relay is burned (replace).
The pump does not work (repair/replace).
1.
2.
1.
2.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 45
DUST CONTROL SYSTEM
NOZZLE AND FILTER CLEANING
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed
air or water gun.
Preliminary operations
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Cleaning of nozzles and fi lters on brooms
Unscrew the ring nuts (A).
Clean the nozzles (B) and fi lters (C) with compressed air. Remove calcium deposits. If necessary, replace the fi lters (C).
Install the fi lters and nozzles, and secure them with the ring nuts. Nozzle holes must be directed down when tightening.
Cleaning of nozzles inside the suction inlet
On both sides of the suction inlet (D), remove the screws (E) together with the nozzles (F).
Clean the nozzles (F) and screws (E) with compressed air. Remove calcium deposits.
Assemble the components in the reverse order of disassembly.
Cleaning of nozzle and fi lter in the rear suction pipe
Remove the screw (G), the nozzle (H) and the fi lter (I).
Clean the nozzle (H) and fi lter (I) with compressed air. Remove calcium deposits. If necessary, replace the fi lter (I).
Assemble the components in the reverse order of disassembly.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
46 33015500(3)2008-02 RS 501
DUST CONTROL SYSTEM
NOZZLE AND FILTER CLEANING (Continues)
F
D
E
F
E
G
H
I
A
A
B
C
S301490
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 47
DUST CONTROL SYSTEM
WATER FILTER CLEANING
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed
air or water gun.
NOTE
When the fi lter is removed, the water inside the tanks comes out up to the fi lter level.
Preliminary operations
Turn the ignition key (76) to OFF position and remove it.
Engage the parking brake with the lever (66).
In the area over the rear axle (15), remove the water fi lter cover (A) together with the fi lter (B).
Separate the fi lter (B) from the cover (A), then wash and clean it. If necessary, replace the fi lter (B).
Install the fi lter (B) and the cover (A).
If necessary, fi ll the water tanks.
B
A
A
S301491
1.
2.
3.
4.
5.
6.
ENGLISH SERVICE MANUAL
48 33015500(3)2008-02 RS 501
DUST CONTROL SYSTEM
WATER TANK EMPTYING
When necessary, empty the dust control system water tanks (7 and 16) according to the following procedure.
Turn the ignition key (76) to OFF position and remove it.
Engage the parking brake with the lever (66).
Remove the water tank drain plugs (A) and (B) and drain all the water from the tanks.
Install the plugs (A) and (B).
A
B
S301492
1.
2.
3.
4.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 49
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:
Oil pump
Priority valve
Steering gearbox
Rear wheel control hydraulic cylinder
Hydraulic system oil tank
Hydraulic system hoses
CBA
E
F
D
S300878
A)
B)
C)
D)
E)
F)
ENGLISH SERVICE MANUAL
50 33015500(3)2008-02 RS 501
STEERING SYSTEM
TROUBLESHOOTING
The machine does not move straightforward
Possible causes:
The rear axle toe-in is incorrect (adjust).
The steering is hard
Possible causes:
The steering gearbox is faulty (replace).
The priority valve is faulty (replace).
The rear wheel control hydraulic cylinder is faulty (replace).
1.
1.
2.
3.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 51
STEERING SYSTEM
REAR AXLE TOE-IN ADJUSTMENT
Drive the machine on a solid and level ground and keep the rear wheels (A) in a straightforward position, then engage the
parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Prepare two metal plates (B) to be used as reference lines. The plates must be a little longer than the wheel diameter.
Place the plates (B) on the external surface of the wheels (A), at the centre of the wheels and parallel to the ground, as shown
in the fi gure.
Do not place the plates (B) where the tire surface is irregular.
Keeping the plates (B) in the above-mentioned position, check that the distances (E) and (F), measured on the front and on
the back of the wheels (A), are the same. A maximum difference of 4 mm between the two distances is admitted. If necessary,
adjust the distances by loosening the nuts (D) and turning the tie rods (C). Then tighten the nuts (D).
B
A
E
A
B
F
B
A
A
B
S300879
1.
2.
3.
4.
5.
ENGLISH SERVICE MANUAL
52 33015500(3)2008-02 RS 501
STEERING SYSTEM
REAR AXLE TOE-IN ADJUSTMENT (Continues)
D
CC
D
S300880
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 53
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:
Brake pedal
Brake fl uid pump
Hydraulic system oil tank
Cylinders
Pipes
Drum brakes
The parking brake is mechanic, manually controlled, and actuates on the drum brakes of the front wheels.
The parking brake consists of:
Parking brake lever
Bracket
Control cable
Drum brakes
G
CA
E
B
E
EII
H
D
FD
F
S300881
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
ENGLISH SERVICE MANUAL
54 33015500(3)2008-02 RS 501
BRAKE SYSTEM
TROUBLESHOOTING
The machine brake system is not effi cient
Possible causes:
The brake fl uid is insuffi cient (check the fl uid level).
The brake fl uid pump is faulty (overhaul).
There is air in the system (bleed).
The drum brake cylinder is faulty (replace).
The braking masses are worn or greasy (replace).
The parking brake is not effi cient
Possible causes:
The brake is misadjusted (adjust).
1.
2.
3.
4.
5.
1.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 55
BRAKE SYSTEM
BRAKE FLUID LEVEL CHECK
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 fl uid level in the tank (A) is approximately at 1 cm from the fi ller neck.If necessary, top up using the same type
of fl uid that is in the line.Type of fl uid used: DOT4.
Close the right lid (20).
A
S301618
1.
2.
3.
5.
ENGLISH SERVICE MANUAL
56 33015500(3)2008-02 RS 501
BRAKE SYSTEM
PARKING BRAKE CHECK AND ADJUSTMENT
Check
Engage the parking brake lever (66) and check for proper operation. Check also that the brake operates in the same way on
both the front wheels.
If necessary, adjust the parking brake according to the following procedure.
Adjustment
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
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).
Perform steps 4, 5, 6, 7 and 9 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
BC
F
I
I
E
G
D
H
S300883
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
•
•
11.
12.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 57
BRAKE SYSTEM
PARKING BRAKE CONTROL CABLE REPLACEMENT
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
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, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
F
E
G
D
C
S300884
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
ENGLISH SERVICE MANUAL
58 33015500(3)2008-02 RS 501
BRAKE SYSTEM
PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues)
H
I
K
L
P
M
N
LL
N
M
O
S300885
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 59
BRAKE SYSTEM
BRAKE SYSTEM CHECK
Check the brake fl uid 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).
1.
2.
3.
4.
5.
ENGLISH SERVICE MANUAL
60 33015500(3)2008-02 RS 501
BRAKE SYSTEM
BRAKING MASSES REPLACEMENT
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
F
G
E
E
G
F
H
S300886
1.
2.
3.
4.
5.
6.
7.
8.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 61
BRAKE SYSTEM
BRAKE SYSTEM BLEEDING
WARNING!
Brake system bleeding must be always performed with the system opened.
It must also be performed on both front wheels.
Check the brake fl uid level (see the procedure in the relevant paragraph).
Remove one of the front wheels (see the procedure in the relevant paragraph).
Place safety stands under the machine side sill, on the side where the wheel has been removed.
Remove the brake system bleed valve plug (A) and connect the pipe (B) to bleed the fl uid.
Press the brake pedal (57) until the pedal resistance increases. In this condition, keep the pedal pressed and unscrew the
valve (A) slightly. Let the oil and air bleed from the pipe (B) into the container (C) until no more air comes out, but oil only. Then
screw down the valve (A) and release the brake pedal (57).
Perform steps 2 to 4 in the reverse order.
Bleed the brake system also on the other front wheel, by performing steps from 2 to 6 again.
BA
C
S300887
1.
2.
3.
4.
5.
6.
7.
ENGLISH SERVICE MANUAL
62 33016312(0)2007-04 RS 501 UK
BRAKE SYSTEM
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 63
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:
Drive pedal
Right drive system motor
Left drive system motor
Drive system pump
Hydraulic system oil tank
Hoses
CBA
E
F
D
S300878
A)
B)
C)
D)
E)
F)
ENGLISH SERVICE MANUAL
64 33015500(3)2008-02 RS 501
DRIVE SYSTEM
TROUBLESHOOTING
The machine stability is reduced
Possible causes:
The tires are not correctly infl ated (check tire pressure).
The rear axle is noisy
Possible causes:
The wheel bearings are worn (replace).
The machine power is reduced
Possible causes:
The drive system motors are worn (replace).
The drive pedal is faulty (replace).
The drive system pump power decreases (check the oil pressure at the drive system pump).
The machine does not move
Possible causes:
The drive system pump deactivation screw for machine pushing/towing is unscrewed (screw down).
There are oil leaks from the hydraulic system (repair).
The drive system pump is broken (replace).
The drive system motor is broken (replace).
The machine moves even if the drive pedal is released
Possible causes:
The drive pedal is misadjusted (adjust).
1.
1.
1.
2.
3.
1.
2.
3.
4.
1.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 65
DRIVE SYSTEM
TIRE PRESSURE CHECK
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
The tire pressure should be as follows:
Front tires: 3.75 Bar
Rear tires: 3.75 Bar
S301511
1.
2.
3.
•
•
ENGLISH SERVICE MANUAL
66 33015500(3)2008-02 RS 501
DRIVE SYSTEM
REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR
ADJUSTMENT
Check
Check that, when the machine moves in reverse, the relevant buzzer sounds.
If necessary, adjust the relevant sensor according to the following procedure.
Adjustment
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Check that the surface (A) of the sensor (B) is fl ush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
Check that the distance between the sensor surface (A) and the bracket (E) is within 1.5 and 2.5 mm. When checking, move
the drive pedal (F) towards the bracket (E) to cancel the drive pedal end play.
If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed,
tighten the nuts (G) and (H).
Perform step 1 again.
F
AC
EG
H
G
E
DB
S301410
1.
2.
3.
4.
5.
6.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 67
DRIVE SYSTEM
REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY
Disassembly
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Cut the cable clamp (A) under the right side of the cab.
Disconnect the reverse gear buzzer activation sensor connector (B).
Remove the four mounting screws (D) of the drive pedal (E).
Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).
Remove the sensor (C), the harness (G) and the connector.
Assembly
Assemble the components in the reverse order of disassembly.
Adjust the reverse gear buzzer activation sensor (see the procedure in the relevant paragraph).
AA
B
E
D
C
D
FCG
S301411
1.
2.
3.
4.
5.
6.
7.
8.
9.
ENGLISH SERVICE MANUAL
68 33015500(3)2008-02 RS 501
DRIVE SYSTEM
WHEEL REMOVAL/INSTALLATION
Preliminary operations
Turn the ignition key (76) to OFF position and remove it.
Engage the parking brake with the lever (66).
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.
Remove the wheel according to the following procedure.
Rear wheel removal/installation
Place the jack (A) (not equipped) under the relevant housing (D) in the rear axle (B), as shown in the fi gure.
Carefully activate the jack (A), and lift the wheel (C) until it is slightly detached from the ground.
Remove the mounting nuts, then remove the wheel (C).
Install the wheel (C) by performing steps from 5 to 7 in the reverse order.
Wheel mounting nut tightening torque: 400 N·m
Front wheel removal/installation
Place the jack (E) (not equipped) under the relevant housing (F) on the machine side sill, in front of the wheel (G), as shown in
the fi gure.
Carefully activate the jack (E) (not equipped), and lift the wheel (G) until it is slightly detached from the ground.
Remove the mounting nuts, then remove the wheel.
Install the wheel by performing steps from 9 to 11 in the reverse order.
Wheel mounting nut tightening torque: 400 N·m
S301412
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 69
DRIVE SYSTEM
DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY
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 fi ve screws (G), then remove the drive system motor (B) together with the brake.
Assemble the components in the reverse order of disassembly and note the following:
Before assembling the wheel, bleed the brake system (see the procedure in the relevant paragraph).
Check the brake system (see the procedure in the relevant paragraph).
Adjust the parking brake (see the procedure in the relevant paragraph).
G
F
C
B
E
A
D
GB
S300891
1.
2.
3.
4.
5.
6.
7.
•
8.
9.
ENGLISH SERVICE MANUAL
70 33015500(3)2008-02 RS 501
DRIVE SYSTEM
DRIVE PEDAL CHECK AND ADJUSTMENT
Preliminary operations
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Check
Drive the machine on a level and smooth ground, and, with the engine on, check that the machine does not move forward or
backward when the drive pedal (56) is not pressed.
If the machine moves, even though slightly, check the drive pedal, according to the following procedure.
Drive pedal check
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position.
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
Disengage the parking brake with the lever (66).
Stop the left front wheel with two wedges (A).
Remove the right front wheel according to the procedure shown in the relevant paragraph.
Place safety stands under the machine side sill, on the side where the wheel has been removed.
Lift the hopper (3) for 20 cm, according to the procedure shown in the User Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right lid (20) by releasing the fasteners (21) with the supplied key.
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant 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.
Turn on the diesel engine with care.
WARNING!
When the diesel engine is running, the wheel hub (B) can be rotating.
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).
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position.
Perform steps 6 to 12 in the reverse order.
Perform step 1 again.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
•
•
•
17.
18.
19.
20.
21.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 71
DRIVE SYSTEM
DRIVE PEDAL CHECK AND ADJUSTMENT (Continues)
A
B
C
D
E
S301494
ENGLISH SERVICE MANUAL
72 33016312(0)2007-04 RS 501 UK
DRIVE SYSTEM
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 73
LDW 1603/B2 ENGINE
LDW 1603/B2 ENGINE
DESCRIPTION
The machine is equipped with a diesel engine, which activates the hydraulic system pumps.
For diesel engine data see the Technical Data chapter and the Diesel Engine Manual.
The following pumps are connected to the engine:
Accessory and steering system pump
Suction fan pump
Drive system pump
The fuel fi lter is located on the machine frame.
For machines equipped with climate control system, besides the alternator control pulley, there is also the compressor control pulley
(D).
A
B
C
D
S301413
A)
B)
C)
ENGLISH SERVICE MANUAL
74 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
TROUBLESHOOTING
The diesel engine does not start
Possible causes:
The drive pedal is pressed (release).
The sensor for engine start-up inhibition is misadjusted/broken (adjust/replace).
NOTE
For diesel engine complete troubleshooting, see the relevant Manual.
1.
2.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 75
LDW 1603/B2 ENGINE
ENGINE OIL LEVEL CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
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, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
ENGLISH SERVICE MANUAL
76 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
ENGINE OIL CHANGE
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Change 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, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 77
LDW 1603/B2 ENGINE
ENGINE OIL FILTER CHANGE
NOTE
This procedure must be performed when the engine oil has been drained.
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Replace the oil fi lter according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
78 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
ENGINE COOLANT LEVEL CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
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.
A
B
S300894
1.
2.
3.
4.
5.
6.
7.
•
•
8.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 79
LDW 1603/B2 ENGINE
ENGINE AIR FILTER CLEANING
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning operations using compressed air
gun.
Preliminary operations
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Open the left lid (18) by releasing the fasteners (19) with the supplied key.
Pre-fi lter cleaning
Remove the screw (A), then remove the pre-fi lter (B).
Clean and wash the pre-fi lter, then install it.
Filter cleaning
Remove the screw (C), then remove the cover (D).
Remove the outer fi lter (E) and the inner fi lter (F).
Clean the fi lters (E) and (F) carefully with compressed air (maximum 6 Bar) and replace them, if necessary.
Install the fi lters (E) and (F).
Install the cover (D) and the screw (C).
Close the left lid (18) by engaging the fasteners (19) with the supplied key.
ABCD
EF
S300895
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
80 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
FUEL FILTER REPLACEMENT
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Replace the fuel fi lter according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 81
LDW 1603/B2 ENGINE
FUEL FITTING AND SCREW CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Operating on the fuel fi lter (A) and on the diesel engine, check the sealing of fuel system fi ttings (B). Repair if necessary.
Operating on the fuel tank (C), check the sealing of fuel system fi ttings (D). Repair if necessary.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
B
B
BBBB
D
C
D
A
S301656
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
ENGLISH SERVICE MANUAL
82 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
ALTERNATOR BELT TENSION CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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 and, if necessary, adjust the alternator belt tension according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 83
LDW 1603/B2 ENGINE
ALTERNATOR BELT REPLACEMENT
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Replace and adjust the alternator belt tension according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
84 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
RADIATOR FIN CLEANING CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Check the radiator fi n cleaning according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 85
LDW 1603/B2 ENGINE
ENGINE COOLANT LINE SLEEVE CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Check the coolant line sleeves according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
86 33015500(3)2008-02 RS 501
LDW 1603/B2 ENGINE
ENGINE COOLANT CHANGE
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Change the engine coolant according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 87
LDW 1603/B2 ENGINE
INJECTOR CALIBRATION AND CLEANING
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Calibrate and clean the injectors according to the procedure shown in the Diesel Engine Manual.
Perform steps 3 to 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
88 33016312(0)2007-04 RS 501 UK
LDW 1603/B2 ENGINE
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 89
CLIMATE CONTROL SYSTEM
CLIMATE CONTROL SYSTEM
DESCRIPTION
The climate control system consists of:
Compressor
Condenser
Cooler
Expansion valve
Filter drier
High pressure hose
Low pressure hose
High pressure connection
Low pressure connection
Cooling controls
Heating controls
Heater
Air fi lter
MC
D
G
IA
F
H
B
E
L
K
J
S300899
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
ENGLISH SERVICE MANUAL
90 33015500(3)2008-02 RS 501
CLIMATE CONTROL SYSTEM
TROUBLESHOOTING
No fresh air from the climate control system
Possible causes:
The compressor does not turn because the drive belt is loosen/broken (tension/replace the belt).
There are gas leaks from the system (repair the leak and integrate the gas).
The expansion valve is faulty (replace).
No hot air from the climate control system
Possible causes:
The hot water hoses are broken (replace).
There are water leaks from the heater (replace).
1.
2.
3.
1.
2.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 91
CLIMATE CONTROL SYSTEM
COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine)
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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).
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
A
C
D
B
E
S301415
1.
2.
3.
4.
5.
6.
7.
8.
9.
•
10.
11.
ENGLISH SERVICE MANUAL
92 33015500(3)2008-02 RS 501
CLIMATE CONTROL SYSTEM
COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine)
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
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, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
B
A
C
S301415
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 93
CLIMATE CONTROL SYSTEM
AIR FILTER REPLACEMENT
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 fi lter (D).
Install the new fi lter (D) with the arrows (E) pointing in the direction of the air fl ow (upwards).
Perform steps 3 and 4 in the reverse order.
DE
A
A
AAFCF
B
S300902
1.
2.
3.
4.
5.
6.
7.
ENGLISH SERVICE MANUAL
94 33016312(0)2007-04 RS 501 UK
CLIMATE CONTROL SYSTEM
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 95
OTHER SYSTEMS
OTHER SYSTEMS
NUT AND SCREW TIGHTENING AND LEAKAGE CHECK
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
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.
Remove the screw (42) and open the left tank (41).
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 fl uids (oil, etc.).
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
•
•
•
•
11.
12.
ENGLISH SERVICE MANUAL
96 33015500(3)2008-02 RS 501
OTHER SYSTEMS
LUBRICATION
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
S300903
1.
2.
3.
•
•
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 97
OTHER SYSTEMS
CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE
PEDAL IS PRESSED
Check
Check that it is not possible to start the machine with the ignition key (76) when the drive pedal (56) is pressed.
If necessary, adjust the relevant sensor according to the following procedure.
Adjustment
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Check that the surface (A) of the sensor (B) is fl ush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
Check that the distance between the sensor surface (A) and the bracket (E) is within 1.5 and 2.5 mm. When checking, move
the drive pedal (F) towards the bracket (E) to cancel the drive pedal end play.
If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed,
tighten the nuts (G) and (H).
Perform step 1 again.
F
DB
AC
E
G
H
G
S301453
1.
1.
2.
3.
4.
5.
ENGLISH SERVICE MANUAL
98 33015500(3)2008-02 RS 501
OTHER SYSTEMS
DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE
PEDAL IS PRESSED
Disassembly
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Cut the cable clamp (A) under the right side of the cab.
Disconnect the connector (B) of the sensor for engine start-up inhibition (C).
Remove the four mounting screws (D) of the drive pedal (E).
Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).
Remove the sensor (C), the harness (G) and the connector.
Assembly
Assemble the components in the reverse order of disassembly.
Adjust the sensor for engine start-up inhibition (see the procedure in the relevant paragraph).
AA
B
E
D
D
FCG
S301416
1.
2.
3.
4.
5.
6.
7.
8.
9.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 99
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
DESCRIPTION
The hydraulic system consists of three independent circuits, supplied by one tank.
The fi rst 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 fi lters and safety valves.
NOTE
The hydraulic system hoses are DIN type.
COMPONENT LOCATION
Hydraulic system oil tank
Drain fi lter
Suction fi lter
Suction fi lter
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 fi lter
Drive system pump oil fi lter
High-pressure washing system pump (*)
Flow regulator (*)
Hydraulic system oil fi ller plug
Hydraulic system oil level indicator
(*) Optional for some countries.
–
–
–
–
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.
ENGLISH SERVICE MANUAL
100 33015500(3)2008-02 RS 501
HYDRAULIC SYSTEM
COMPONENT LOCATION (Continues)
57
76
69
52-53
64
75
8161
51
79
60
65
70
54-78
55
80
58-73
72
74
71
68
59 63
56
62 67
66
65
82
50
S301619
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 101
HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM
Hydraulic system oil tank
Drain fi lter
Suction fi lter
Suction fi lter
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 fi lter
Drive system pump oil fi lter
High-pressure washing system pump (*)
Flow regulator (*)
Breather/fi ller plug
(*) Optional for some countries.
(**) A version: 150 cc
B version, standard: 175 cc
C version: 200 cc
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.
ENGLISH SERVICE MANUAL
102 33015500(3)2008-02 RS 501
HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM (Continues)
ABPT
M
ab
10µm
60µm
60µm
50
77
52 53
DX
SX
68
69
70
55 62 63
73
59
61
66
66
67
60
65
71
74
72
54
64
56 57
80cc
30bar
80cc
130bar
8.1cc
CAPACITÀ SERBATOIO/TANK CAPACITY: 40.6 lt.(10.73 U.S. gal.)
CAPACITÀ IMPIANTO/SYSTEM CAPACITY: 58 lt.(15.32 U.S. gal.)
40cc
18bar
90bar
21cc
11.23cc
14.1cc
210bar
58
8.7 l/min
13.1 l/min 150bar
150bar
Versione [B] / [B] Version : 175cc
(Standard)
250bar
250bar
Versione [C] / [C] Version : 200cc
2600 RPM
(MAX)
76
75
51
60µm
10µm
79
ASPIRAZIONE ACQUA/
WATER INLET
USCITÀ ACQUA/
WATER OUTLET
C1 C2
B
A
78
T
P
B
A
13
2
80
PT
B1
A1
A
1
2
3
4
P
B2
A2
102
13
2
1:1
1:1
9cc
A
B
M1
M2
L1
T
P
R
L
A
A
A
A
A
A
A
A
A
P1 L2
A
B
A
B
EV3
EV2
A
50X350X 35
40X95X 20
40X95X 20
N 2 48X85 32
40X70X 25
T
B
A
B
T
P
S
81
10µm
21.8 l/min
A
A
A
A
B
B
c
S301497
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 103
HYDRAULIC SYSTEM
TROUBLESHOOTING
See the previous chapters related to the use of the hydraulic system.
ENGLISH SERVICE MANUAL
104 33015500(3)2008-02 RS 501
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
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 effi ciency indicator (D) of the drain fi lter (C) is in the green area (E), otherwise the fi lter (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.
Screw down the plug (G).
Close the right lid (20) by engaging the fasteners (21) with the supplied key.
S301620
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 105
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL CHANGE
CAUTION!
This procedure must be performed with the hopper (3) fully retracted (as shown in the fi gure).
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.
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 fi ller plug (B).
If necessary replace the drain fi lter (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 fi ller 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).
Screw down the fi ller plug (B).
Close the right lid (20) by engaging the fasteners (21) with the supplied key.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
ENGLISH SERVICE MANUAL
106 33015500(3)2008-02 RS 501
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL CHANGE (Continues)
AE
S301621
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 107
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL SUCTION FILTER REPLACEMENT
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
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 fi lters (C) inside the tank.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and fi lters should be disposed of properly according to the environmental Laws in
force.
Remove any debris and dirt from the tank.
Clean the tank upper perimeter edge (F) and the matching profi le (D) of the cover (B).
Install the new fi lters (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
S301622
1.
2.
3.
4.
5.
6.
7.
8.
ENGLISH SERVICE MANUAL
108 33015500(3)2008-02 RS 501
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
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 fi lters should be disposed of properly according to the environmental Laws in
force.
Remove the drain fi lter (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.
S301623
1.
2.
3.
4.
5.
6.
7.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 109
HYDRAULIC SYSTEM
DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT
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.
Remove the screw (A) and the fi lter (B) behind the right front wheel.
If necessary, to reach the fi lter, 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 fi lters should be disposed of properly according to the environmental Laws in
force.
Install a new fi lter (B) and fasten it with the screw (A).
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
A
B
S300910
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
ENGLISH SERVICE MANUAL
110 33015500(3)2008-02 RS 501
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.
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 fi ns (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
S301624
1.
2.
3.
4.
5.
6.
7.
8.
9.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 111
HYDRAULIC SYSTEM
REAR WHEEL CONTROL HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY
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) fi xing 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).
BC
C
D
D
A
A
S300912
1.
2.
3.
4.
5.
6.
7.
8.
ENGLISH SERVICE MANUAL
112 33015500(3)2008-02 RS 501
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.
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.
Perform steps 2 to 5 in the reverse order.
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)
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.
Perform steps 3 to 8 in the reverse order.
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).
–
–
–
1.
2.
3.
4.
5.
6.
7.
–
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 113
HYDRAULIC SYSTEM
HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY (Continues)
A
C
B
D
S300913
ENGLISH SERVICE MANUAL
114 33015500(3)2008-02 RS 501
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.
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.
Loosen the locknut (C) and remove the lever (B).
Remove the screws (D), then remove the control valve assembly (A).
If necessary, remove the fi ttings 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).
CAB
D
S301512
1.
2.
3.
4.
5.
6.
7.
8.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 115
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.
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 fi ttings 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).
Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
B
D
C
A
S301513
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
ENGLISH SERVICE MANUAL
116 33015500(3)2008-02 RS 501
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 fi gure).
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
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.
Remove the retaining clamps (C) of the exhaust manifold (D), then move the exhaust manifold.
Mark the position of the hoses connected to the fi ttings (E) of the accessory pump (F) (for proper reassembly).
Disconnect the hoses from the fi ttings (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 fi ttings 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).
Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 117
HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
(Continues)
S300916
ENGLISH SERVICE MANUAL
118 33015500(3)2008-02 RS 501
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 fi gure).
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
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.
Mark the position of the hoses connected to the fi ttings (E) of the accessory pump (F) (for proper reassembly).
Disconnect the hoses from the fi ttings (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 fi ttings 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).
Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
If necessary, fi ll the dust control system water tanks according to the procedure shown in the User Manual.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 119
HYDRAULIC SYSTEM
ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine)
(Continues)
C
C
E
G
F
G
G
G
E
S301423
ENGLISH SERVICE MANUAL
120 33015500(3)2008-02 RS 501
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.
Remove the suction inlet (see the procedure in the relevant paragraph).
Mark the position of the hoses connected to the fi ttings (A) of the suction fan pump (B) (for proper reassembly).
Disconnect the hoses from the fi ttings (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.
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 fi ttings 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).
C
A
D
B
A
C
D
B
S301424
1.
2.
3.
4.
5.
6.
7.
8.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 121
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.
Remove the suction inlet (see the procedure in the relevant paragraph).
Mark the position of the hoses connected to the fi ttings (A) of the drive system pump (B) and of the suction fan pump (C) (for
proper reassembly).
Disconnect the hoses from the fi ttings (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.
Remove the screws (E), then remove the pumps (B) and (C) with the relevant joints.
If necessary, remove the drive system pump fi ttings 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).
E
A
FC
A
A
A
A
DB
S301425
1.
2.
3.
4.
5.
6.
7.
8.
ENGLISH SERVICE MANUAL
122 33015500(3)2008-02 RS 501
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
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.
Remove the screws and the right panel (22) on the right side of the cab.
Connect a pressure gauge (E), with a minimum scale of 250 Bar equipped with the extension, to the pressure intake (C).
Measure the suction fan pump pressure according to the following procedure.
Pressure measurement
Start the machine and run the engine at maximum speed (as shown in the User Manual). 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
Unscrew the cap (G).
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).
Disengage the lever (F) and turn off the machine.
Tighten the locknut (H) and screw down the cap (G).
Reset
Perform steps 3 and 4 in the reverse order.
1.
2.
3.
4.
5.
6.
•
•
7.
8.
9.
10.
11.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 123
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP (Continues)
H
I
C
E
F
G
S301500
ENGLISH SERVICE MANUAL
124 33015500(3)2008-02 RS 501
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
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).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the right panel (22) on the right side of the cab.
Connect a pressure gauge (E) with a minimum scale of 150 Bar equipped with the extension.
Measure the accessory and steering system pump pressure according to the following procedure.
Pressure measurement
Start the machine and run the engine at maximum speed (as shown in the User Manual). 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
Unscrew the cap (G).
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).
Disengage the lever (F) and turn off the machine.
Tighten the locknut (H) and screw down the cap (G).
Reset
Perform steps 4 and 5 in the reverse order.
1.
2.
3.
4.
5.
6.
7.
•
•
8.
9.
10.
11.
12.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 125
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP
(Continues)
G
E
C
F
HI
S301501
ENGLISH SERVICE MANUAL
126 33015500(3)2008-02 RS 501
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
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 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.
Turn the ignition key (76) to OFF position and remove it.
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.
Measure the drive system pump pressure according to the following procedure.
Pressure measurement
Start the machine and run the engine at maximum speed (as shown in the User Manual).
Fully engage the parking brake with the lever (66).
WARNING!
To perform the inspection, indicated in the next step 9, in a safe condition, keep the personnel away from the
front of the machine and remove any obstructions.
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 fi rmly 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 specifi ed, check if the fault is related to the drive system pump or to the drive pedal assist.
Reset
Perform steps 4 and 5 in the reverse order.
1.
2.
3.
4.
5.
6.
7.
8.
9.
•
•
10.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 127
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP (Continues)
B
A
S301502
ENGLISH SERVICE MANUAL
128 33016312(0)2007-04 RS 501 UK
HYDRAULIC SYSTEM
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 129
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
AA Horn
AS Cigarette lighter
B 12 V battery
B1 Engine coolant temperature bulb
B2 Engine oil bulb
B3 Engine coolant warning light bulb
B4 Parking brake microswitch
B5 Lifted hopper microswitch
B6 Brake light microswitch
B7 Hydraulic system oil cooler fan bulb
B8 Reverse gear sensor
BX Engine start safety sensor
C1 Ignition switch
C2 Combination switch
C3 Warning buzzer/parking brake buzzer
C4 Reverse gear buzzer
C5 Hour counter/revolution counter/water temperature indicator
C6 Climate control system compressor
D1 Diode
D2 Diode
EV1 Fuel solenoid valve
EV2 Skirt solenoid valve
EV3 Skirt solenoid valve
F1A Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)
F2A Fuel solenoid valve fuse (10 A)
F3A Cab blower/fl ashing light/windscreen wiper fuse (15 A)
F4A Dust control system water pump fuse (10 A)
Dust control system water pump/climate control system (optional) fuse
(20 A)
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
L3 Right front turn signal
L4 Left rear turn signal
L5 Left brake light
L6 Right brake light
L7 Left front running light
L8 Right rear running light
L9 Right front running light
L10 Left rear running light
L11 Left low beam
L12 Right low beam
L13 Left high beam
L14 Right high beam
L15 Flashing light
L16 Licence plate light
M1 Starter
M2 Hydraulic system oil cooler fan motor
M3 Windscreen wiper motor
M4 Dust control system water pump (normal)
M5 Cab blower motor
M6 Climate control system blower motor
M7 Windscreen washer motor with tank
M8 Hopper lid opening/closing electric jack motor
P Climate control system pressure switch
R1 Engine glow plug control unit relay
R2 General relay
R3 Reverse gear buzzer relay
R4 Turn signal intermittence relay
R5 Water pump relay
R6 Climate control system compressor relay (*)
R7 Climate control system condenser fan relay (*)
RS Cab blower resistance
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
(*) Optional for some countries.
ENGLISH SERVICE MANUAL
130 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)
L15
EV2-EV3
L2
L6
L8
L16
C4
L10
L5
L4
M4
P
M2-B7
M5
L1
L7-L11-L13
L3
M1C6
K-A-B1-B2-B3 (*)
B5 G1
M6
L9-L12-L14
AA
G2
B
TM
RS
EV1
M8
AS
M7
S301503
(*) See the Diesel Engine Manual
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 131
ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)
RY RX R7 R6 R4 R3
R1
D1-D2
R5 R2
I1
B4
B6
B8 BX
M3
C2
S301504
ENGLISH SERVICE MANUAL
132 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
COMPONENT LOCATION (Continues)
F1A
F2A
F3A
F4A
F5A
F6A
F1B
F2B
F3B
F4B
F5B
F6B
S11
S9-I2
I5-S14
I3-S12
I4-S13 I7-S17 C1
S6
C3
S8
S7
S2
S5
S1
G2
C5
S10
S3
S4
S16
F7A
F8A
I6-S15
F7B
S301505
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 133
ELECTRICAL SYSTEM
WIRING DIAGRAM
A Alternator
AA Horn
AS Cigarette lighter
B 12 V battery
B1 Engine coolant temperature bulb
B2 Engine oil bulb
B3 Engine coolant warning light bulb
B4 Parking brake microswitch
B5 Lifted hopper microswitch
B6 Brake light microswitch
B7 Hydraulic system oil cooler fan bulb
B8 Reverse gear sensor
BX Engine start safety sensor
C1 Ignition switch
C2 Combination switch
C3 Warning buzzer/parking brake buzzer
C4 Reverse gear buzzer
C5 Hour counter/revolution counter/water temperature indicator
C6 Climate control system compressor
D1 Diode
D2 Diode
EV1 Fuel solenoid valve
EV2 Skirt solenoid valve
EV3 Skirt solenoid valve
F1A Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)
F2A Fuel solenoid valve fuse (10 A)
F3A Cab blower/fl ashing light/windscreen wiper fuse (15 A)
F4A Dust control system water pump fuse (10 A)
Dust control system water pump/climate control system
(optional) fuse (20 A)
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
L3 Right front turn signal
L4 Left rear turn signal
L5 Left brake light
L6 Right brake light
L7 Left front running light
L8 Right rear running light
L9 Right front running light
L10 Left rear running light
L11 Left low beam
L12 Right low beam
L13 Left high beam
L14 Right high beam
L15 Flashing light
L16 Licence plate light
M1 Starter
M2 Hydraulic system oil cooler fan motor
M3 Windscreen wiper motor
M4 Dust control system water pump (normal)
M5 Cab blower motor
M6 Climate control system blower motor
M7 Windscreen washer motor with tank
M8 Hopper lid opening/closing electric jack motor
P Climate control system pressure switch
R1 Engine glow plug control unit relay
R2 General relay
R3 Reverse gear buzzer relay
R4 Turn signal intermittence relay
R5 Water pump relay
R6 Climate control system compressor relay (*)
R7 Climate control system condenser fan relay (*)
RS Cab blower resistance
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
(*) Optional for some countries.
ENGLISH SERVICE MANUAL
134 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
WIRING DIAGRAM (Continues)
F6A
K
M1
87a 85
B1
B
-
+
Rx
85
87a
Ry
30 86
30 86
85
R1 30
L
T
50
86
87
15/54
C1
02
1
30
50
F7A F5A
F2A
C5
B4
A
EV1
85
R2
30
S1
86 87
Bx
B5
S6
S4
S3
S2
B2 B3
S16 C3
G2
C4
30
87a
R3
85
86
S5 B8
31
15
30
2.0
4.0
15/54
RD
BK
RD
RD
BU-BK
BN-BK
GY-RD
RD
VT-RD
BK
BN-BK
BK
BN
RD
VT-RD VT-RD
BK
BU-BK
GY-RD GY-RD GY-RD
PK-WH PK-WH PK-WH
BK
PK-BK
BK
RD
LIGHT PK
LIGHT BU-WH
BK
OG-GN
BK
PK-YE
GY-GN
RD-BK
PK-WH
BK
OG-GN
BK
BN-BK
(*)
(*)
S301506
(*) Continues to the next page
Color code
BK Black
BU Blue
BN Brown
GN Green
GY Grey
OG Orange
PK Pink
RD Red
VT Violet
WH White
YE Yellow
LIGHT BU Light blue
LIGHT PK Light pink
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 135
ELECTRICAL SYSTEM
WIRING DIAGRAM (Continues)
EV2 EV3
L7 S7L8 L9 L10 L16
F3B F4B
1
032
1/3 C2
F8A
S17
M8
I7
1/3 C2
F1A F2B
F1B
0
M2
B7
I1
I 0 II
1
L4L1 L2 L3 L5 L6
7
S10
120
1/3 C2
R4
I2
34 61
28
5
S9
10
B6
AA
C
1
31
15
30
31
15
30
15/54
4.2
2.2
BN-BK
PK-YE
PK-BK
BK
PK-YE
BU-BK
BU
WH-YE
WH-RD
WH-GN
YE-GN
YE-RD
OG
OG-RD
BK
BK
WH
OG
BU-WH
BK
BK
OG
LIGHT BU
LIGHT BU
BU
BU
BU
BU
BU
YE-RD
RD RD
BN-BK
YE
YE YE
GY-YE
VT
YE-RD GY-YE GY-YE YE-RD
GY-YE
GY-YE
BK
BU
(**)
(**)
(**)
(*)
(*)
S301506
(*) Continues from the previous page (**) Continues to the next page
ENGLISH SERVICE MANUAL
136 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
WIRING DIAGRAM (Continues)
L11 L12 S8
L13 L14L14
F5B F6B
M7 M3
L15 G1
M4
S11
M5
87
R5
85
86
S12
I3
7
429
II I0510
I4
3
I05
87a
30
RS
D2
I5
S13 02 1
D1
S14
F4A F3A
C6
M6
TM
R6
85 87
86 30
P
R7
85 87
86 30
I6
251
2
I
03
6
S15
F7B
AS
31
15
30
4.3
2.3
GY-YE
VT
GY-BK
GY
VT-BK VT
VT-BK
WH-RD
BU-RD
BU-RD
BK
RD
BK
WH-RD
BK
WH-YE
WH
WH-RD
WH-BU
PK
WH
WH-BU
BU-BK
OG
GN-WH
GY-BK
WH-RD
BK
WH-RD
GY-RD
WH-RD
WH
BN
YE-GN
BK
BK
(**)
(**)
(**)
S301506
(**) Continues from the previous page
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 137
ELECTRICAL SYSTEM
TROUBLESHOOTING
See the previous chapters related to the use of the electrical system.
Other possible causes:
The fuses are burnt (replace).
The harness is cut or pressed (repair).
1.
2.
ENGLISH SERVICE MANUAL
138 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
BATTERY FLUID LEVEL CHECK
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing battery check and cleaning procedures.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the left panel (23) in the cab.
Check the electrolyte level in the battery (A) and, if necessary, top up.
If necessary, clean the battery.
Check the battery terminal connections for oxidation.
Install the left panel (23) in the cab and the screws.
A
S301507
1.
2.
3.
4.
5.
6.
7.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 139
ELECTRICAL SYSTEM
FUSE REPLACEMENT
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
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)
Free fuse holder
Fuse box A
Hydraulic system oil cooler fan/skirt solenoid valve fuse (20 A)
Fuel solenoid valve fuse (10 A)
Cab blower/fl ashing 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)
Install the transparent cover of the fuse box (A) or (B).
ijklmn
A
B
abcdef
A
B
op
gh
S301429
1.
2.
3.
A)
B)
C)
D)
E)
F)
G)
H)
I)
J)
K)
L)
M)
N)
O)
P)
4.
ENGLISH SERVICE MANUAL
140 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
RELAY REPLACEMENT
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
RX R7 R6 R4 R3 R5 R2
R1 RY
S301508
1.
2.
3.
4.
•
•
•
•
•
•
•
•
•
5.
SERVICE MANUAL ENGLISH
RS 501 33015500(3)2008-02 141
ELECTRICAL SYSTEM
CONTROL PANEL DISPLAY REPLACEMENT
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).
EI
H
F
G
J
A
C
DC
S301509
1.
2.
3.
4.
5.
6.
7.
8.
9.
ENGLISH SERVICE MANUAL
142 33015500(3)2008-02 RS 501
ELECTRICAL SYSTEM
LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT
Preliminary operations
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.
Bulb replacement
Remove the screws (A) and move the headlight (B).
Replace the burned bulbs.
Install the headlight (B) and fasten it with the screws (A).
Adjust the headlights according to the following procedure.
Low beam adjustment
Use the screws (C) and (D), in the following way:
To adjust the beam vertically, turn the screws (C) and (D) simultaneously;
To adjust the beam horizontally, turn the screws (C) and (D) individually.
C
AB
A
D
S300929
1.
2.
3.
4.
5.
6.
7.
•
•
