RS 501 ENGLISH SERVICE MANUAL 33015499(3)2008-02
SERVICE MANUAL ENGLISH TABLE OF CONTENTS GENERAL INFORMATION .............................................................................................................................................. 3 MACHINE LIFTING ......................................................................................................................................................................... 3 MACHINE TRANSPORT ..................................................................................................
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE .................................................................................................................................................. 73 DESCRIPTION .............................................................................................................................................................................. 73 TROUBLESHOOTING ................................................................................................................
SERVICE MANUAL ENGLISH 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.
ENGLISH SERVICE MANUAL GENERAL INFORMATION GENERAL SAFETY INSTRUCTIONS Specific warnings and cautions to inform about potential damages to people and machine are shown below. DANGER! This machine must be used by properly trained and authorised personnel only. – Moreover, the operator must: – • Be of full age • Have a driving license • Be in normal psycho-physical conditions • Not be under the effect of substances that alters the nervous system (alcohol, psycopharmaceuticals, drugs, etc.
SERVICE MANUAL ENGLISH 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.
ENGLISH SERVICE MANUAL 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
SERVICE MANUAL ENGLISH 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.
ENGLISH SERVICE MANUAL 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.
SERVICE MANUAL ENGLISH GENERAL INFORMATION MAINTENANCE The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance. WARNING! See GENERAL INFORMATION and SAFETY paragraphs. The following table provides the scheduled maintenance. The intervals shown may vary according to particular working conditions, which are to be defined by the person in charge of the maintenance.
ENGLISH SERVICE MANUAL GENERAL INFORMATION Running-in period (after the first 50 hours) Maintenance Every 10 hours or before use Every 200 hours Every 600 hours Every 1,200 hours Every 2,400 hours Long periods Lubrication Engine coolant line sleeve check (7) Drive system pump oil filter check Hydraulic system oil drain filter replacement Hydraulic system oil suction filter replacement Alternator belt replacement (3) Cab air filter replacement (1) Injector calibration and cleaning (2) (3) C
SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE Throughout this Manual you will find numbers in brackets, for example: (2). These numbers refer to the components indicated in these two nomenclature pages. Refer to these pages whenever it will be necessary to identify a component mentioned in the text. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
ENGLISH SERVICE MANUAL GENERAL INFORMATION 107. Hopper manual lifting hand pump lever 108. High-pressure water gun 109. Serial number plate/technical data/certification marking 110. Right water tank drain plug 111. Left water tank drain plug 112. High-pressure washing system pressure gauge 113. Breather filter hood 114. Hydraulic system oil filler plug 115. Hydraulic system pressure intake (on drive system pump) 116. Hydraulic system pressure intake (at suction fan pump) 117.
SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) 18 14 1 99 100 45 104 112 19 12 103 25 10 111 7 11 113 101 3 2 8 20 6 13 115 17 102 24 21 26 98 9 8 97 15 4 9 110 16 S301479 RS 501 33015500(3)2008-02 13
SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) 5 105 48 26 40 32 28 27 31 46 30 29 118 47 38 39 114 106 128 33 36 107 37 51 41 49 44 42 50 35 43 S301617 14 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) 58 119 108 54 59 61 65 55 66 60 64 62 68 67 63 69 53 57 121 120 52 123 109 22 122 56 124 125 116 126 117 34 23 127 S301481 RS 501 33015500(3)2008-02 15
ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) 78 1 70 80 79 81 77 71 73 74 72 83 82 75 96 76 84 95 85 94 93 86 87 88 92 91 89 90 S301407 16 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH SWEEPING SYSTEM SWEEPING SYSTEM DESCRIPTION The sweeping system consists of: A) Right side broom B) Left broom C) Broom arms The brooms (A) and (B) are supported by arms (C) which are fastened to the machine frame. Broom rotation is activated by hydraulic motors. For proper sweeping and conveyance of dust and debris towards the suction inlet: – Broom height and tilting must be properly adjusted; – Proper brooms must be used according to the type of ground to be cleaned.
ENGLISH SERVICE MANUAL SWEEPING SYSTEM TROUBLESHOOTING The brooms do not clean correctly Possible causes: 1. The brooms are not adjusted correctly (adjust). 2. The broom speed is not correct (adjust). The brooms do not rotate Possible causes: 1. There are oil leaks from the hydraulic system hoses (replace the hoses). 2. The hydraulic motors are faulty (replace). 3. The accessory system hydraulic pump does not pressurize the oil in the circuit (check the hydraulic system oil pressure).
SERVICE MANUAL ENGLISH SWEEPING SYSTEM SIDE BROOM POSITION CHECK AND ADJUSTMENT NOTE Brooms of various hardness are available. This procedure is applicable to all types of brooms. Check 1. Check the side brooms for proper height and tilting, according to the following procedure: • Drive the machine on a level ground. • While keeping the machine stationary, fully lower the side brooms and allow them to rotate for a few seconds. • Stop and lift the side brooms, then move the machine.
ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues) S301482 20 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH SWEEPING SYSTEM BROOM REPLACEMENT NOTE Brooms of various hardness are available. This procedure is applicable to all types of brooms. CAUTION! It is advisable to use protective gloves when cleaning the side brooms because there can be sharp debris between the bristles. 1. 2. 3. 4. 5. 6. 7. Lift the brooms and engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the centre screw (A), then remove the broom (B) to be replaced.
ENGLISH SERVICE MANUAL SWEEPING SYSTEM BROOM SPEED ADJUSTMENT Speed measurement 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. Connect a speed measurement indicator with a portable tachometer to the broom (10) or (11). 4. Start the machine and run the engine at maximum speed and set the broom speed adjuster (127) to maximum speed (as shown in the User Manual). In this condition, measure the broom speed with the portable tachometer.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM DUST AND DEBRIS COLLECTION SYSTEM DESCRIPTION The dust and debris collection system consists of: A) B) C) D) E) F) G) H) I) J) K) L) M) N) Q) Suction fan Dust and debris suction filter Hopper Suction hose Suction inlet Skirt Gasket between suction inlet and hopper Hopper lid Hopper suction hole Open lid support rod Lifted hopper locking pins Lifted hopper locking pins housing Lifted hopper locking pins holes Air breather filter Hopper lid suction s
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM DESCRIPTION (Continues) A N G B D E C I F P K J O K K H M Q L S301483 24 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM TROUBLESHOOTING The suction fan turns but it is not efficient Possible causes: 1. The filters are clogged (clean). 2. The suction hose is clogged (clean). 3. The suction hose is cut/torn (replace). 4. The gasket between the suction inlet and the hopper is broken or misadjusted (replace or adjust). 5. The hopper lid gasket is broken (replace). 6. There is no pressure at the suction fan motor drive pump (adjust the pump pressure).
ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun. Preliminary operations 1. Empty the hopper (3), drive the machine to a cleaning/washing appointed area, then engage the parking brake with the lever (66). 2. Lift and dump the hopper (3), according to the procedure shown in the User Manual. 3.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues) D T A B C D F E U H G K L J I S300862 RS 501 33015500(3)2008-02 27
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues) M N O P V R S300863 28 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK Preliminary operations 1. Engage the parking brake with the lever (66). 2. Lift the suction inlet (12), according to the procedure shown in the User Manual. 3. Turn the ignition key (76) to OFF position and remove it. Suction inlet wheel check 4.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK (Continues) G C A G H A B E F D G F L J A I K N O S301484 30 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY NOTE To remove the rear wheel (C), the machine must be lifted with an appropriate hoisting system. Otherwise, remove the suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following disassembling procedures. Front wheels (A) and (B) removal/installation 1. Engage the parking brake with the lever (66). 2.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY NOTE To remove the suction inlet sliding panels, the machine must be lifted with an appropriate hoisting system. Otherwise, remove the suction inlet assembly (D) according to the procedure shown in the relevant paragraph. See the following disassembling procedures. 1. 2. 3. 4. 5. 6. Place the machine on the appropriate hoisting system (if present) and lift it.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION INLET DISASSEMBLY/ASSEMBLY Disassembly 1. Remove the side brooms (see the procedure in the relevant paragraph). 2. Lower the suction inlet (12), according to the procedure shown in the User Manual. 3. Engage the parking brake with the lever (66). 4. Turn the ignition key (76) to OFF position and remove it. 5. Disconnect the hydraulic system hoses (A) and (B) from the suction inlet (C) and plug them. 6.
ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM SKIRT REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Lower the suction inlet (12), according to the procedure shown in the User Manual. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the clip (A) and the skirt (B). Remove the screws (C), then remove the skirt (D). Install the new skirt (D) and fasten it with the screws (C). Install the skirt (B) and the clip (A).
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER POSITION ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER POSITION ADJUSTMENT (Continues) D D A B A C B C E E F G I H J L S300869 36 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER LID CLOSING ACTUATOR ADJUSTMENT Preliminary operations 1. Empty the hopper (3), according to the procedure shown in the User Manual. 2. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). 3. Lift the hopper (3), according to the procedure shown in the User Manual. 4. Turn the ignition key (76) to OFF position and remove it. 5.
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER LID CLOSING ACTUATOR ADJUSTMENT (Continues) P Q G F I N J H L D O E K S300965 38 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY Disassembly 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. With a ladder and the help of an assistant, disengage the fasteners (A) of the breather filter hood (B). 4. Open the hood (C) and install the safety pin (D). 5. Remove the mounting screws (E), then remove the breather filter (F). 6.
ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues) Q N H N G J K M L R P O S301488 40 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM SUCTION HOSE DISASSEMBLY/ASSEMBLY Preliminary operations 1. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. 2. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). 3. Lift the hopper (3), according to the procedure shown in the User Manual. 4. Turn the ignition key (76) to OFF position and remove it. 5.
ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM 42 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH DUST CONTROL SYSTEM DUST CONTROL SYSTEM DESCRIPTION The dust control system consists of: A) Right water tank B) Left water tank C) Tank filler plugs D) Broom nozzles E) Suction inlet nozzles F) Water filter G) Hose H) Water level indicator Nozzle pump I) J) Taps K) Rear suction pipe nozzle L) Opening tap M) Tank drain plugs The water gun connected to the dust control system consists of: N) Water gun pump O) Quick coupling P) Water gun Q) Hose R) Reel S) Pressure gauge Q R O S C
ENGLISH SERVICE MANUAL DUST CONTROL SYSTEM TROUBLESHOOTING No water from the nozzles Possible causes: 1. The water filter is clogged (clean/replace). 2. The nozzles are clogged (clean). No water to the nozzles Possible causes: 1. The water pump relay is burned (replace). 2. The pump does not work (repair/replace).
SERVICE MANUAL ENGLISH DUST CONTROL SYSTEM NOZZLE AND FILTER CLEANING WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun. Preliminary operations 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. Cleaning of nozzles and filters on brooms 3. Unscrew the ring nuts (A). 4. Clean the nozzles (B) and filters (C) with compressed air. Remove calcium deposits.
ENGLISH SERVICE MANUAL DUST CONTROL SYSTEM NOZZLE AND FILTER CLEANING (Continues) C A B A E E D F F H I G S301490 46 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH DUST CONTROL SYSTEM WATER FILTER CLEANING WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun. NOTE When the filter is removed, the water inside the tanks comes out up to the filter level. Preliminary operations 1. Turn the ignition key (76) to OFF position and remove it. 2. Engage the parking brake with the lever (66). 3.
ENGLISH SERVICE MANUAL DUST CONTROL SYSTEM WATER TANK EMPTYING When necessary, empty the dust control system water tanks (7 and 16) according to the following procedure. 1. Turn the ignition key (76) to OFF position and remove it. 2. Engage the parking brake with the lever (66). 3. Remove the water tank drain plugs (A) and (B) and drain all the water from the tanks. 4. Install the plugs (A) and (B).
SERVICE MANUAL ENGLISH 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.
ENGLISH SERVICE MANUAL STEERING SYSTEM TROUBLESHOOTING The machine does not move straightforward Possible causes: 1. The rear axle toe-in is incorrect (adjust). The steering is hard Possible causes: 1. The steering gearbox is faulty (replace). 2. The priority valve is faulty (replace). 3. The rear wheel control hydraulic cylinder is faulty (replace).
SERVICE MANUAL ENGLISH STEERING SYSTEM REAR AXLE TOE-IN ADJUSTMENT 1. 2. 3. 4. 5. Drive the machine on a solid and level ground and keep the rear wheels (A) in a straightforward position, then engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Prepare two metal plates (B) to be used as reference lines. The plates must be a little longer than the wheel diameter.
ENGLISH SERVICE MANUAL STEERING SYSTEM REAR AXLE TOE-IN ADJUSTMENT (Continues) C C D D S300880 52 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH BRAKE SYSTEM BRAKE SYSTEM DESCRIPTION The machine is equipped with an hydraulic brake system controlled by pedal, which actuates on the drum brakes of the front wheels. The brake system consists of: A) Brake pedal B) Brake fluid pump C) Hydraulic system oil tank D) Cylinders E) Pipes F) Drum brakes The parking brake is mechanic, manually controlled, and actuates on the drum brakes of the front wheels.
ENGLISH SERVICE MANUAL BRAKE SYSTEM TROUBLESHOOTING The machine brake system is not efficient Possible causes: 1. The brake fluid is insufficient (check the fluid level). 2. The brake fluid pump is faulty (overhaul). 3. There is air in the system (bleed). 4. The drum brake cylinder is faulty (replace). 5. The braking masses are worn or greasy (replace). The parking brake is not efficient Possible causes: 1. The brake is misadjusted (adjust).
SERVICE MANUAL ENGLISH BRAKE SYSTEM BRAKE FLUID LEVEL CHECK 1. 2. 3. 5. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Open the right lid (20). Check that the fluid level in the tank (A) is approximately at 1 cm from the filler neck.If necessary, top up using the same type of fluid that is in the line.Type of fluid used: DOT4. Close the right lid (20).
ENGLISH SERVICE MANUAL BRAKE SYSTEM PARKING BRAKE CHECK AND ADJUSTMENT Check 1. Engage the parking brake lever (66) and check for proper operation. Check also that the brake operates in the same way on both the front wheels. If necessary, adjust the parking brake according to the following procedure. Adjustment 2. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. 3.
SERVICE MANUAL ENGLISH BRAKE SYSTEM PARKING BRAKE CONTROL CABLE REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
SERVICE MANUAL ENGLISH BRAKE SYSTEM PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues) H I K L P O M M N N L L S300885 58 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH BRAKE SYSTEM BRAKE SYSTEM CHECK 1. 2. 3. 4. 5. Check the brake fluid level (see the procedure in the relevant paragraph). Press the brake pedal (57) several times, and check that brakes operate properly. Check that there are no leaks from the brake system. If necessary, check/replace the brakes (see the procedure in relevant paragraph). If necessary, bleed the brake system (see the procedure in the relevant paragraph).
SERVICE MANUAL ENGLISH BRAKE SYSTEM BRAKING MASSES REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Remove the front wheel (see the procedure in the relevant paragraph). Place safety stands under the machine side sill, on the side where the wheel has been removed. Remove the screw (A) and the screws (B), then remove the washer (C). Remove the drum (D). Remove the three springs (E). Remove the shoe retaining springs (F).
SERVICE MANUAL ENGLISH BRAKE SYSTEM BRAKE SYSTEM BLEEDING WARNING! Brake system bleeding must be always performed with the system opened. It must also be performed on both front wheels. 1. 2. 3. 4. 5. 6. 7. Check the brake fluid level (see the procedure in the relevant paragraph). Remove one of the front wheels (see the procedure in the relevant paragraph). Place safety stands under the machine side sill, on the side where the wheel has been removed.
ENGLISH SERVICE MANUAL BRAKE SYSTEM 62 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH 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.
ENGLISH SERVICE MANUAL DRIVE SYSTEM TROUBLESHOOTING The machine stability is reduced Possible causes: 1. The tires are not correctly inflated (check tire pressure). The rear axle is noisy Possible causes: 1. The wheel bearings are worn (replace). The machine power is reduced Possible causes: 1. The drive system motors are worn (replace). 2. The drive pedal is faulty (replace). 3. The drive system pump power decreases (check the oil pressure at the drive system pump).
SERVICE MANUAL ENGLISH DRIVE SYSTEM TIRE PRESSURE CHECK 1. 2. 3. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. The tire pressure should be as follows: • Front tires: 3.75 Bar • Rear tires: 3.
SERVICE MANUAL ENGLISH DRIVE SYSTEM REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR ADJUSTMENT Check 1. Check that, when the machine moves in reverse, the relevant buzzer sounds. If necessary, adjust the relevant sensor according to the following procedure. Adjustment 2. Engage the parking brake with the lever (66). 3. Turn the ignition key (76) to OFF position and remove it. 4. Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
SERVICE MANUAL ENGLISH DRIVE SYSTEM REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY Disassembly 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. Cut the cable clamp (A) under the right side of the cab. 4. Disconnect the reverse gear buzzer activation sensor connector (B). 5. Remove the four mounting screws (D) of the drive pedal (E). 6. Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C). 7.
ENGLISH SERVICE MANUAL DRIVE SYSTEM WHEEL REMOVAL/INSTALLATION Preliminary operations 1. Turn the ignition key (76) to OFF position and remove it. 2. Engage the parking brake with the lever (66). 3. Check that the machine cannot move with one wheel lifted (the parking brake operates only on the front wheels). If necessary keep the machine stationary by placing wedges on the wheels contacting the ground. 4. Remove the wheel according to the following procedure. Rear wheel removal/installation 5.
SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the suction inlet (see the procedure in the relevant paragraph). Remove the front wheel (see the procedure in the relevant paragraph). Place safety stands under the machine side sill, on the side where the wheel has been removed. Disconnect the brake system pipes (A) from the brake assembly (B) and plug them immediately.
ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT Preliminary operations 1. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Check 2. Drive the machine on a level and smooth ground, and, with the engine on, check that the machine does not move forward or backward when the drive pedal (56) is not pressed. If the machine moves, even though slightly, check the drive pedal, according to the following procedure. Drive pedal check 3.
SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT (Continues) A B C D E S301494 RS 501 33015500(3)2008-02 71
ENGLISH SERVICE MANUAL DRIVE SYSTEM 72 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE LDW 1603/B2 ENGINE DESCRIPTION The machine is equipped with a diesel engine, which activates the hydraulic system pumps. For diesel engine data see the Technical Data chapter and the Diesel Engine Manual. The following pumps are connected to the engine: A) Accessory and steering system pump B) Suction fan pump C) Drive system pump The fuel filter is located on the machine frame.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE TROUBLESHOOTING The diesel engine does not start Possible causes: 1. The drive pedal is pressed (release). 2. The sensor for engine start-up inhibition is misadjusted/broken (adjust/replace). NOTE For diesel engine complete troubleshooting, see the relevant Manual.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE ENGINE OIL LEVEL CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE ENGINE OIL CHANGE 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE ENGINE OIL FILTER CHANGE NOTE This procedure must be performed when the engine oil has been drained. 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE ENGINE COOLANT LEVEL CHECK 1. 2. 3. 4. 5. 6. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE ENGINE AIR FILTER CLEANING WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning operations using compressed air gun. Preliminary operations 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. Open the left lid (18) by releasing the fasteners (19) with the supplied key. Pre-filter cleaning 4. Remove the screw (A), then remove the pre-filter (B). 5.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE FUEL FILTER REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE FUEL FITTING AND SCREW CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE ALTERNATOR BELT TENSION CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the right lid (20) by releasing the fasteners (21) with the supplied key.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE ALTERNATOR BELT REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the right lid (20) by releasing the fasteners (21) with the supplied key.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE RADIATOR FIN CLEANING CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE ENGINE COOLANT LINE SLEEVE CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE ENGINE COOLANT CHANGE 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
SERVICE MANUAL ENGLISH LDW 1603/B2 ENGINE INJECTOR CALIBRATION AND CLEANING 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the left lid (18) by releasing the fasteners (19) with the supplied key.
ENGLISH SERVICE MANUAL LDW 1603/B2 ENGINE 88 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH CLIMATE CONTROL SYSTEM CLIMATE CONTROL SYSTEM DESCRIPTION The climate control system consists of: A) Compressor B) Condenser C) Cooler D) Expansion valve E) Filter drier F) High pressure hose G) Low pressure hose H) High pressure connection Low pressure connection I) J) Cooling controls K) Heating controls L) Heater M) Air filter J B E F K L H G I A D M C S300899 RS 501 33015500(3)2008-02 89
ENGLISH SERVICE MANUAL CLIMATE CONTROL SYSTEM TROUBLESHOOTING No fresh air from the climate control system Possible causes: 1. The compressor does not turn because the drive belt is loosen/broken (tension/replace the belt). 2. There are gas leaks from the system (repair the leak and integrate the gas). 3. The expansion valve is faulty (replace). No hot air from the climate control system Possible causes: 1. The hot water hoses are broken (replace). 2. There are water leaks from the heater (replace).
SERVICE MANUAL ENGLISH CLIMATE CONTROL SYSTEM COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine) 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
ENGLISH SERVICE MANUAL CLIMATE CONTROL SYSTEM COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine) 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it.
SERVICE MANUAL ENGLISH CLIMATE CONTROL SYSTEM AIR FILTER REPLACEMENT 1. 2. 3. 4. 5. 6. 7. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the screws (A) and the panel (B) in the cab. Unscrew the knobs (F) and remove the panel (C). Remove the cab air filter (D). Install the new filter (D) with the arrows (E) pointing in the direction of the air flow (upwards). Perform steps 3 and 4 in the reverse order.
ENGLISH SERVICE MANUAL CLIMATE CONTROL SYSTEM 94 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH OTHER SYSTEMS OTHER SYSTEMS NUT AND SCREW TIGHTENING AND LEAKAGE CHECK 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Open the right and left lids (20) and (18) by releasing the fasteners (21) and (19) with the supplied key. Lift the hopper (3), according to the procedure shown in the User Manual.
ENGLISH SERVICE MANUAL OTHER SYSTEMS LUBRICATION 1. 2. 3. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Lubricate the rear axle knuckles with the grease nipples (A). If necessary, steer the rear wheels to reach the grease nipples easily. Grease quantity to be applied: • 2 - 3 pumping, in case of a manual pump. • 8 - 12 seconds of injection, in case of an air pump.
SERVICE MANUAL ENGLISH OTHER SYSTEMS CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE PEDAL IS PRESSED Check 1. Check that it is not possible to start the machine with the ignition key (76) when the drive pedal (56) is pressed. If necessary, adjust the relevant sensor according to the following procedure. Adjustment 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3.
ENGLISH SERVICE MANUAL OTHER SYSTEMS DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN THE DRIVE PEDAL IS PRESSED Disassembly 1. Engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. Cut the cable clamp (A) under the right side of the cab. 4. Disconnect the connector (B) of the sensor for engine start-up inhibition (C). 5. Remove the four mounting screws (D) of the drive pedal (E). 6.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM DESCRIPTION The hydraulic system consists of three independent circuits, supplied by one tank. The first circuit is supplied by a variable delivery pump, activated by the diesel engine. This pump activates two drive system motors, which operate on the front wheels. The forward and reverse drive speed is adjusted by the drive pedal, which is connected to the pump. The second circuit is supplied by a gear pump, activated by the diesel engine.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM COMPONENT LOCATION (Continues) 51 61 81 82 50 69 52-53 76 64 74 57 72 79 75 58-73 80 65 62 67 70 66 68 56 59 71 55 54-78 63 60 65 S301619 100 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC DIAGRAM 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81.
102 11.23cc 33015500(3)2008-02 A P B T RS 501 64 A P USCITÀ ACQUA/ WATER OUTLET B 71 14.1cc B L1 57 18bar A DX M1 M2 10µm 77 A 50 A 250bar 250bar 54 52 60µm a A A b A 51 P T 53 55 70 1 21.8 l/min 69 2 A 3 A 68 T 90bar P 80cc 13.1 l/min A 62 A 130bar A1 B1 8.7 l/min 80cc 40cc 63 58 CAPACITÀ SERBATOIO/TANK CAPACITY: 40.6 lt.(10.73 U.S. gal.) A CAPACITÀ IMPIANTO/SYSTEM CAPACITY: 58 lt.(15.32 U.S. gal.) 1:1 2600 RPM (MAX) M 10µm 78 8.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the hydraulic system.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK CAUTION! This procedure must be performed with the hopper (3) fully retracted. 1. 2. 3. 4. 5. 6. 7. 8. Engage the parking brake with the lever (66). Start the diesel engine and run it at 1,500 rpm, according to the procedure shown in the User Manual. Open the right lid (20) by releasing the fasteners (21) with the supplied key.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL CHANGE CAUTION! This procedure must be performed with the hopper (3) fully retracted (as shown in the figure). 1. 2. 3. 4. 5. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Open the right lid (20) by releasing the fasteners (21) with the supplied key. Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL CHANGE (Continues) A E S301621 106 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL SUCTION FILTER REPLACEMENT CAUTION! This procedure must be performed with the hopper (3) fully retracted. 1. 2. 3. If necessary, bleed the hydraulic system oil from the tank (see the procedure in the relevant paragraph). Remove the screws (A), then remove the tank cover (B) without damaging the gasket (E). Unscrew and remove the suction filters (C) inside the tank. WARNING! Hydraulic system oil is highly corrosive, wear rubber gloves.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT CAUTION! This procedure must be performed with the hopper (3) fully retracted. 1. 2. 3. 4. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Open the right lid (20) by releasing the fasteners (21) with the supplied key. Unscrew and remove the cover (A). WARNING! Hydraulic system oil is highly corrosive, wear rubber gloves.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Lift the hopper (3), according to the procedure shown in the User Manual. Turn the ignition key (76) to OFF position and remove it. Open the right lid (20) by releasing the fasteners (21) with the supplied key.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed air or water gun. 1. 2. 3. 4. 5. 6. 7. 8. 9. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM REAR WHEEL CONTROL HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Disconnect the hoses (A) from the rear wheel control hydraulic cylinder (B) and plug them immediately. Unscrew the fasteners (C) fixing the cylinder to the steering tie rods. Remove the screws (D), then remove the cylinder (B).
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY CAUTION! If necessary, remove the bonded sealing washers and replace them. Disassembly/assembly of the following hydraulic cylinders: Suction inlet right cylinder (A) – Suction inlet left cylinder (A) – Skirt cylinder (C) – CAUTION! This procedure must be performed with the hopper (3) fully retracted. 1. 2. 3. 4. Engage the parking brake with the lever (66). Bring the suction inlet in the most suitable position.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY (Continues) A C B D S300913 RS 501 33015500(3)2008-02 113
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM SUCTION FAN CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION CAUTION! This procedure must be performed with the hopper (3) fully lowered. CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. Remove the screws and the right panel (22) on the right side of the cab. Disconnect all the hoses from the suction fan control valve assembly (A) and plug them immediately. WARNING! Hydraulic system oil is highly corrosive, wear rubber gloves. 3. 4. 5.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM ACCESSORY SYSTEM CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION CAUTION! This procedure must be performed with the hopper (3) fully lowered. CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. 3. 4. If necessary, bleed the hydraulic system oil from the tank (see the procedure in the relevant paragraph). Remove the screws and the right panel (22) on the right side of the cab.
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) CAUTION! This procedure must be performed with the hopper (3) fully retracted (as shown in the figure). CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) (Continues) S300916 RS 501 33015500(3)2008-02 117
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) (Continues) CAUTION! This procedure must be performed with the hopper (3) fully retracted (as shown in the figure). CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. 3. 4. 5. 6. 7. 8. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine) (Continues) C C E G F G G E G S301423 RS 501 33015500(3)2008-02 119
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY CAUTION! This procedure must be performed with the hopper (3) fully retracted. CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. 3. Remove the suction inlet (see the procedure in the relevant paragraph). Mark the position of the hoses connected to the fittings (A) of the suction fan pump (B) (for proper reassembly).
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM DRIVE SYSTEM PUMP DISASSEMBLY/ASSEMBLY CAUTION! This procedure must be performed with the hopper (3) fully retracted. CAUTION! If necessary, remove the bonded sealing washers and replace them. 1. 2. 3. Remove the suction inlet (see the procedure in the relevant paragraph). Mark the position of the hoses connected to the fittings (A) of the drive system pump (B) and of the suction fan pump (C) (for proper reassembly).
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP NOTE This check is necessary in case of malfunction of the suction fan. Preliminary operations 1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. 3. Remove the screws and the right panel (22) on the right side of the cab. 4.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP (Continues) F C G E H I S301500 RS 501 33015500(3)2008-02 123
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP NOTE This check is necessary in case of malfunction of the accessory system and steering system. Preliminary operations 1. Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it. 2. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). 3. Turn the ignition key (76) to OFF position and remove it. 4.
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP (Continues) C F G E H I S301501 RS 501 33015500(3)2008-02 125
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP NOTE This check is necessary in case of malfunction of the drive system. Preliminary operations 1. Empty the hopper (3). If it contains a small quantity of waste, it is not necessary to dump it. 2. Drive the machine on a solid and level ground and engage the parking brake with the lever (66).
SERVICE MANUAL ENGLISH HYDRAULIC SYSTEM HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP (Continues) A B S301502 RS 501 33015500(3)2008-02 127
ENGLISH SERVICE MANUAL HYDRAULIC SYSTEM 128 33016312(0)2007-04 RS 501 UK
SERVICE MANUAL ENGLISH 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).
ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) L15 EV2-EV3 M2-B7 P M8 M4 L4 L5 L10 L2 L6 L8 C4 L16 M6 G2 B5 G1 AS AA M7 B L3 M5 RS TM C6 M1 EV1 K-A-B1-B2-B3 (*) L9-L12-L14 L1 L7-L11-L13 S301503 (*) See the Diesel Engine Manual 130 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) RY RX R7 R1 R6 R4 R3 R5 R2 D1-D2 C2 B4 B6 M3 I1 B8 BX S301504 RS 501 33015500(3)2008-02 131
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) F1A F2A F5A F7A F3A F4A F6A F8A F7B C3 S6 F1B F6B F4B F2B F3B F5B I3-S12 S9-I2 I6-S15 I5-S14 I7-S17 S11 I4-S13 C1 G2 S8 S10 S3 S4 S7 S2 S5 S1 S16 C5 S301505 132 33015500(3)2008-02 RS 501
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM A AA AS B B1 B2 B3 B4 B5 B6 B7 B8 BX C1 C2 C3 C4 C5 C6 D1 D2 EV1 EV2 EV3 F1A F2A F3A F4A F5A F6A F7A F8A F1B F2B F3B F4B F5B F6B F7B G1 G2 I1 I2 I3 I4 I5 I6 I7 Alternator Horn Cigarette lighter 12 V battery Engine coolant temperature bulb Engine oil bulb Engine coolant warning light bulb Parking brake microswitch Lifted hopper microswitch Brake light microswitch Hydraulic system oil cooler fan bulb Reverse gear sensor Engine start safety sensor Ign
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) (*) 4.0 31 30 15 15/54 2.
(*) (*) 31 S17 PK-YE PK-YE I7 BK BU-BK PK-BK M8 EV2 I1 I 0 II EV3 WH-GN B7 F1A YE-GN M2 YE-RD F8A 1 BK 4 2 L1 0 F1B OG-RD LIGHT BU BU BN-BK BU-WH 3 OG 1 0 2 1/3 C2 R4 6 8 L2 5 OG 30 BU RS 501 L3 1 L4 S10 BU WH I2 S9 10 BK BU BK BK 7 L5 RD F2B L6 RD B6 YE-RD AA 1/3 C2 1 C BU L7 YE-RD GY-YE L8 F3B S7 GY-YE YE 0 1 2 3 BN-BK YE Continues from the previous page L9 GY-YE YE GY-YE L10 F4B 1/3 C2 GY-YE (*) 15 15/54 L16 YE-RD
4.3 2.
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the electrical system. Other possible causes: 1. The fuses are burnt (replace). 2. The harness is cut or pressed (repair).
ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM BATTERY FLUID LEVEL CHECK WARNING! Protect body parts (eyes, hair, hands, etc.) properly, when performing battery check and cleaning procedures. 1. 2. 3. 4. 5. 6. 7. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the screws and the left panel (23) in the cab. Check the electrolyte level in the battery (A) and, if necessary, top up. If necessary, clean the battery.
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM FUSE REPLACEMENT 1. 2. 3. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it.
ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM RELAY REPLACEMENT 1. 2. 3. 4. 5. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the screws (C) and lower the dashboard panel (D) in the cab.
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM CONTROL PANEL DISPLAY REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Engage the parking brake with the lever (66). Turn the ignition key (76) to OFF position and remove it. Remove the screws and the left panel (23) in the cab. Disconnect the negative pin from the battery (A). Remove the screws (C) and lower the dashboard panel (D) in the cab. Remove the screws (E) and lower the display (F). Disconnect the connectors (G) and (H), then recover the display (F).
SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT Preliminary operations 1. Drive the machine on a solid and level ground, then engage the parking brake with the lever (66). 2. Turn the ignition key (76) to OFF position and remove it. Bulb replacement 3. Remove the screws (A) and move the headlight (B). 4. Replace the burned bulbs. 5. Install the headlight (B) and fasten it with the screws (A). 6. Adjust the headlights according to the following procedure.
