Nilfisk-Advance RS 501 Service Manual
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Nilfisk-Advance RS 501 Service Manual

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See also: Instructions for Use Manual , User Manual
RS 501
ENGLISH
SERVICE MANUAL
33015499(3)2008-02

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Summary of Contents for Nilfisk-Advance RS 501

  • Page 1 RS 501 ENGLISH SERVICE MANUAL 33015499(3)2008-02...

  • Page 3: Table Of Contents

    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 RS 501 33015500(3)2008-02...
  • Page 4 WIRING DIAGRAM ..................................133 TROUBLESHOOTING ................................. 137 BATTERY FLUID LEVEL CHECK ..............................138 FUSE REPLACEMENT ................................139 RELAY REPLACEMENT ................................140 CONTROL PANEL DISPLAY REPLACEMENT ........................... 141 LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT ................142 33015500(3)2008-02 RS 501...

  • Page 5: General Information

    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.

  • Page 6: General Safety Instructions

    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. 33015500(3)2008-02 RS 501...
  • Page 7 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. RS 501 33015500(3)2008-02...

  • Page 8: Technical Data

    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 33015500(3)2008-02 RS 501...
  • Page 9 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 RS 501 33015500(3)2008-02...

  • Page 10: Environmental Conditions

    – 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. 33015500(3)2008-02 RS 501...

  • Page 11: Maintenance

    Dust control system water fi lter cleaning Parking brake check Alternator belt tension check Climate control system compressor belt tension check Diesel engine oil fi lter replacement (7)(8) Fuel fi lter replacement Nut and screw tightening and leakage check RS 501 33015500(3)2008-02...
  • Page 12 (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 33015500(3)2008-02 RS 501...

  • Page 13: Machine Nomenclature

    Rear suction pipe fastener Combination switch 103. Front skirt Steering wheel adjusting lever 104. Machine serial number Drive pedal 105. Hopper (dumping position) Brake pedal 106. Suction hose gasket Steering wheel Driver’s seat Suction inlet and brooms control lever RS 501 33015500(3)2008-02...
  • Page 14 Can holder 116. Hydraulic system pressure intake (at suction fan pump) 127. Broom speed adjuster (***) 117. Hydraulic system pressure intake (at accessory and 128. Hydraulic system oil level indicator steering system pump) (*) Optional for some countries. 33015500(3)2008-02 RS 501...
  • Page 15 SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) S301479 RS 501 33015500(3)2008-02...
  • Page 16 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) S301617 33015500(3)2008-02 RS 501...
  • Page 17 SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) S301481 RS 501 33015500(3)2008-02...
  • Page 18 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) S301407 33015500(3)2008-02 RS 501...

  • Page 19: Sweeping System

    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 S300857 RS 501 33015500(3)2008-02...

  • Page 20: Troubleshooting

    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). 33015500(3)2008-02 RS 501...

  • Page 21: Side Broom Position Check And Adjustment

    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. RS 501 33015500(3)2008-02...
  • Page 22 ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues) S301482 33015500(3)2008-02 RS 501...

  • Page 23: Broom Replacement

    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. S300859 RS 501 33015500(3)2008-02...

  • Page 24: Broom Speed Adjustment

    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. S301510 33015500(3)2008-02 RS 501...

  • Page 25: Dust And Debris Collection System

    The suction inlet is made of sheet steel. It is equipped with three wheels, which allow it to follow the pattern of the surface to be cleaned. On its front side there is a skirt (F) that must be lifted to collect bulky debris. RS 501 33015500(3)2008-02...
  • Page 26 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM DESCRIPTION (Continues) S301483 33015500(3)2008-02 RS 501...

  • Page 27: Troubleshooting

    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). RS 501 33015500(3)2008-02...

  • Page 28: Hopper, Filter And Suction Hose Cleaning, And Gasket Check

    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. 33015500(3)2008-02 RS 501...
  • Page 29 SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues) S300862 RS 501 33015500(3)2008-02...
  • Page 30 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues) S300863 33015500(3)2008-02 RS 501...

  • Page 31: Suction Inlet And Skirt Height And Operation Check

    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. RS 501 33015500(3)2008-02...
  • Page 32 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK (Continues) S301484 33015500(3)2008-02 RS 501...

  • Page 33: Suction Inlet Wheel Disassembly/Assembly

    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). S301485 RS 501 33015500(3)2008-02...

  • Page 34: Suction Inlet Sliding Panels Disassembly/Assembly

    (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). S301486 33015500(3)2008-02 RS 501...

  • Page 35: Suction Inlet Disassembly/Assembly

    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). S301487 RS 501 33015500(3)2008-02...

  • Page 36: Skirt Replacement

    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. S300868 33015500(3)2008-02 RS 501...

  • Page 37: Hopper Position Adjustment

    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. RS 501 33015500(3)2008-02...
  • Page 38 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER POSITION ADJUSTMENT (Continues) S300869 33015500(3)2008-02 RS 501...

  • Page 39: Hopper Lid Closing Actuator Adjustment

    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. S300964 RS 501 33015500(3)2008-02...
  • Page 40 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER LID CLOSING ACTUATOR ADJUSTMENT (Continues) S300965 33015500(3)2008-02 RS 501...

  • Page 41: Motor And Suction Fan Disassembly/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). S300870 RS 501 33015500(3)2008-02...
  • Page 42 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues) S301488 33015500(3)2008-02 RS 501...

  • Page 43: Suction Hose Disassembly/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. S300874 RS 501 33015500(3)2008-02...
  • Page 44 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM 33016312(0)2007-04 RS 501 UK...

  • Page 45: Dust Control System

    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 S301489 RS 501 33015500(3)2008-02...

  • Page 46: 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). 33015500(3)2008-02 RS 501...

  • Page 47: Nozzle And Filter Cleaning

    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. RS 501 33015500(3)2008-02...
  • Page 48 ENGLISH SERVICE MANUAL DUST CONTROL SYSTEM NOZZLE AND FILTER CLEANING (Continues) S301490 33015500(3)2008-02 RS 501...

  • Page 49: Water Filter Cleaning

    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. S301491 RS 501 33015500(3)2008-02...

  • Page 50: Water Tank Emptying

    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). S301492 33015500(3)2008-02 RS 501...

  • Page 51: Steering System

    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 S300878 RS 501 33015500(3)2008-02...

  • Page 52: 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). 33015500(3)2008-02 RS 501...

  • Page 53: Rear Axle Toe-In Adjustment

    (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). S300879 RS 501 33015500(3)2008-02...
  • Page 54 ENGLISH SERVICE MANUAL STEERING SYSTEM REAR AXLE TOE-IN ADJUSTMENT (Continues) S300880 33015500(3)2008-02 RS 501...

  • Page 55: Brake System

    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 S300881 RS 501 33015500(3)2008-02...

  • Page 56: Troubleshooting

    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). 33015500(3)2008-02 RS 501...

  • Page 57: Brake Fluid Level Check

    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). S301618 RS 501 33015500(3)2008-02...

  • Page 58: Parking Brake Check And Adjustment

    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. S300883 33015500(3)2008-02 RS 501...

  • Page 59: Parking Brake Control Cable Replacement

    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. S300884 RS 501 33015500(3)2008-02...
  • Page 60 ENGLISH SERVICE MANUAL BRAKE SYSTEM PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues) S300885 33015500(3)2008-02 RS 501...

  • Page 61: Brake System Check

    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). RS 501 33015500(3)2008-02...

  • Page 62: Braking Masses Replacement

    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. S300886 33015500(3)2008-02 RS 501...

  • Page 63: Brake System Bleeding

    (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. S300887 RS 501 33015500(3)2008-02...
  • Page 64 ENGLISH SERVICE MANUAL BRAKE SYSTEM 33016312(0)2007-04 RS 501 UK...

  • Page 65: Drive System

    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 S300878 RS 501 33015500(3)2008-02...

  • Page 66: Troubleshooting

    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). 33015500(3)2008-02 RS 501...

  • Page 67: 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 RS 501 33015500(3)2008-02...

  • Page 68: Reverse Gear Buzzer Check And Reverse Gear Buzzer Activation Sensor Adjustment

    (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. S301410 33015500(3)2008-02 RS 501...

  • Page 69: Reverse Gear Buzzer Sensor Disassembly/Assembly

    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). S301411 RS 501 33015500(3)2008-02...

  • Page 70: Wheel Removal/Installation

    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 33015500(3)2008-02 RS 501...

  • Page 71: Drive System Motor Disassembly/Assembly

    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). S300891 RS 501 33015500(3)2008-02...

  • Page 72: Drive Pedal Check And Adjustment

    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. 33015500(3)2008-02 RS 501...
  • Page 73 SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT (Continues) S301494 RS 501 33015500(3)2008-02...
  • Page 74 ENGLISH SERVICE MANUAL DRIVE SYSTEM 33016312(0)2007-04 RS 501 UK...

  • Page 75: Ldw 1603/B2 Engine

    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). S301413 RS 501 33015500(3)2008-02...

  • Page 76: Troubleshooting

    LDW 1603/B2 ENGINE TROUBLESHOOTING The diesel engine does not start Possible causes: The drive pedal is pressed (release). The sensor for engine start-up inhibition is misadjusted/broken (adjust/replace). NOTE For diesel engine complete troubleshooting, see the relevant Manual. 33015500(3)2008-02 RS 501...

  • Page 77: Engine Oil Level Check

    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. RS 501 33015500(3)2008-02...

  • Page 78: Engine Oil Change

    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. 33015500(3)2008-02 RS 501...

  • Page 79: Engine Oil Filter Change

    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. RS 501 33015500(3)2008-02...

  • Page 80: Engine Coolant Level Check

    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. S300894 33015500(3)2008-02 RS 501...

  • Page 81: Engine Air Filter Cleaning

    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. S300895 RS 501 33015500(3)2008-02...

  • Page 82: Fuel Filter Replacement

    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. 33015500(3)2008-02 RS 501...

  • Page 83: Fuel Fitting And Screw Check

    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. S301656 RS 501 33015500(3)2008-02...

  • Page 84: Alternator Belt Tension Check

    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. 33015500(3)2008-02 RS 501...

  • Page 85: Alternator Belt Replacement

    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. RS 501 33015500(3)2008-02...

  • Page 86: Radiator Fin Cleaning Check

    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. 33015500(3)2008-02 RS 501...

  • Page 87: Engine Coolant Line Sleeve Check

    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. RS 501 33015500(3)2008-02...

  • Page 88: Engine Coolant Change

    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. 33015500(3)2008-02 RS 501...

  • Page 89: Injector Calibration And Cleaning

    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. RS 501 33015500(3)2008-02...
  • Page 90 ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE 33016312(0)2007-04 RS 501 UK...

  • Page 91: 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 S300899 RS 501 33015500(3)2008-02...

  • Page 92: Troubleshooting

    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). 33015500(3)2008-02 RS 501...

  • Page 93: Compressor Belt Tension Check (Ldw 1603/B2 Engine)

    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. S301415 RS 501 33015500(3)2008-02...

  • Page 94: Compressor Belt Replacement (Ldw 1603/B2 Engine)

    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. S301415 33015500(3)2008-02 RS 501...

  • Page 95: Air Filter Replacement

    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. S300902 RS 501 33015500(3)2008-02...
  • Page 96 ENGLISH SERVICE MANUAL CLIMATE CONTROL SYSTEM 33016312(0)2007-04 RS 501 UK...

  • Page 97: Other Systems

    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. RS 501 33015500(3)2008-02...

  • Page 98: Lubrication

    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. S300903 33015500(3)2008-02 RS 501...

  • Page 99: Check And Adjustment Of Sensor For Engine Start-Up Inhibition When The Drive Pedal Is Pressed

    (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. S301453 RS 501 33015500(3)2008-02...

  • Page 100: Disassembly/Assembly Of Sensor For Engine Start-Up Inhibition When The Drive Pedal Is Pressed

    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). S301416 33015500(3)2008-02 RS 501...

  • Page 101: Hydraulic System

    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. RS 501 33015500(3)2008-02...
  • Page 102 ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM COMPONENT LOCATION (Continues) 52-53 58-73 54-78 S301619 33015500(3)2008-02 RS 501...

  • Page 103: Hydraulic Diagram

    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 RS 501 33015500(3)2008-02...
  • Page 104 ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC DIAGRAM (Continues) S301497 33015500(3)2008-02 RS 501...

  • Page 105: Troubleshooting

    SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the hydraulic system. RS 501 33015500(3)2008-02...

  • Page 106: Hydraulic System Oil Level And Drain Filter Efficiency Check

    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 33015500(3)2008-02 RS 501...

  • Page 107: Hydraulic System Oil Change

    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. RS 501 33015500(3)2008-02...
  • Page 108 ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL CHANGE (Continues) S301621 33015500(3)2008-02 RS 501...

  • Page 109: Hydraulic System Oil Suction Filter Replacement

    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). S301622 RS 501 33015500(3)2008-02...

  • Page 110: Hydraulic System Oil Drain Filter Replacement

    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 33015500(3)2008-02 RS 501...

  • Page 111: Drive System Pump Oil Filter Replacement

    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. S300910 RS 501 33015500(3)2008-02...

  • Page 112: Hydraulic System Oil Cooler Fin Cleaning Check

    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. S301624 33015500(3)2008-02 RS 501...

  • Page 113: Rear Wheel Control Hydraulic Cylinder Disassembly/Assembly

    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). S300912 RS 501 33015500(3)2008-02...

  • Page 114: Hydraulic Cylinders Disassembly/Assembly

    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). 33015500(3)2008-02 RS 501...
  • Page 115 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY (Continues) S300913 RS 501 33015500(3)2008-02...

  • Page 116: Suction Fan Control Valve Assembly Removal/Installation

    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). S301512 33015500(3)2008-02 RS 501...

  • Page 117: Accessory System Control Valve Assembly Removal/Installation

    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). S301513 RS 501 33015500(3)2008-02...

  • Page 118: Accessory And Steering System Pump Disassembly/Assembly (Ldw 1603/B2 Engine)

    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. 33015500(3)2008-02 RS 501...
  • Page 119 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) (Continues) S300916 RS 501 33015500(3)2008-02...
  • Page 120 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. 33015500(3)2008-02 RS 501...
  • Page 121 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) (Continues) S301423 RS 501 33015500(3)2008-02...

  • Page 122: Suction Fan Pump Disassembly/Assembly

    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). S301424 33015500(3)2008-02 RS 501...

  • Page 123: Drive System Pump Disassembly/Assembly

    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). S301425 RS 501 33015500(3)2008-02...

  • Page 124: Hydraulic System Oil Pressure Check At The Suction Fan Pump

    (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. 33015500(3)2008-02 RS 501...
  • Page 125 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP (Continues) S301500 RS 501 33015500(3)2008-02...

  • Page 126: Hydraulic System Oil Pressure Check At The Accessory And Steering System Pump

    (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. 33015500(3)2008-02 RS 501...
  • Page 127 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP (Continues) S301501 RS 501 33015500(3)2008-02...

  • Page 128: Hydraulic System Oil Pressure Check On Drive System Pump

    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. 33015500(3)2008-02 RS 501...
  • Page 129 SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP (Continues) S301502 RS 501 33015500(3)2008-02...
  • Page 130 ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM 33016312(0)2007-04 RS 501 UK...

  • Page 131: Electrical System

    Climate control system switch (2 speed/1 speed) Low fuel warning light Electric jack switch Hopper lid opening/closing electric jack warning light Left front turn signal Climate control system thermostat Right rear turn signal Glow plugs Optional for some countries. RS 501 33015500(3)2008-02...
  • Page 132 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) EV2-EV3 M2-B7 B5 G1 K-A-B1-B2-B3 (*) L9-L12-L14 L7-L11-L13 S301503 See the Diesel Engine Manual 33015500(3)2008-02 RS 501...
  • Page 133 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) RY RX R7 R5 R2 R6 R4 D1-D2 S301504 RS 501 33015500(3)2008-02...
  • Page 134 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) S9-I2 I3-S12 I6-S15 I5-S14 I4-S13 I7-S17 S301505 33015500(3)2008-02 RS 501...

  • Page 135: Wiring Diagram

    Climate control system switch (2 speed/1 speed) Blower warning light Electric jack switch Climate control system warning light Low fuel warning light Hopper lid opening/closing electric jack warning light Climate control system thermostat Glow plugs Optional for some countries. RS 501 33015500(3)2008-02...
  • Page 136 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) Color code Black Blue Brown Green Grey Orange Pink Violet White Yellow LIGHT BU Light blue LIGHT PK Light pink S301506 Continues to the next page 33015500(3)2008-02 RS 501...
  • Page 137 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) S301506 Continues from the previous page (**) Continues to the next page RS 501 33015500(3)2008-02...
  • Page 138 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) S301506 (**) Continues from the previous page 33015500(3)2008-02 RS 501...

  • Page 139: Troubleshooting

    SERVICE MANUAL ENGLISH 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). RS 501 33015500(3)2008-02...

  • Page 140: Battery Fluid Level Check

    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. S301507 33015500(3)2008-02 RS 501...

  • Page 141: Fuse Replacement

    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). k l m n b c d e f S301429 RS 501 33015500(3)2008-02...

  • Page 142: Relay Replacement

    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. RX R7 R4 R3 R5 R2 S301508 33015500(3)2008-02 RS 501...

  • Page 143: Control Panel Display Replacement

    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). S301509 RS 501 33015500(3)2008-02...

  • Page 144: Low Beam And High Beam Adjustment And Bulb Replacement

    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. S300929 33015500(3)2008-02 RS 501...

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