RS 501

RS 501
RS 501
Nilfisk
SERVICE MANUAL
502
ENGLISH
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TABLE OF CONTENTS
GENERAL INFORMATION .............................................................................................................................................. 5
MACHINE LIFTING ......................................................................................................................................................................... 5
MACHINE TRANSPORT ................................................................................................................................................................. 5
PUSHING OR TOWING THE MACHINE ......................................................................................................................................... 5
OTHER AVAILABLE MANUALS ...................................................................................................................................................... 5
SAFETY ........................................................................................................................................................................................... 5
GENERAL SAFETY INSTRUCTIONS ............................................................................................................................................. 6
TECHNICAL DATA........................................................................................................................................................................... 8
ENVIRONMENTAL CONDITIONS ................................................................................................................................................. 10
MAINTENANCE ..............................................................................................................................................................................11
SCHEDULED MAINTENANCE TABLE ..........................................................................................................................................11
MACHINE NOMENCLATURE ....................................................................................................................................................... 13
SWEEPING SYSTEM .................................................................................................................................................... 19
DESCRIPTION .............................................................................................................................................................................. 19
TROUBLESHOOTING ................................................................................................................................................................... 20
SIDE BROOM POSITION CHECK AND ADJUSTMENT ............................................................................................................... 21
BROOM REPLACEMENT ............................................................................................................................................................. 23
BROOM SPEED ADJUSTMENT ................................................................................................................................................... 24
DUST AND DEBRIS COLLECTION SYSTEM .............................................................................................................. 25
DESCRIPTION .............................................................................................................................................................................. 25
TROUBLESHOOTING ................................................................................................................................................................... 27
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK ........................................................................... 28
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK ............................................................................................. 30
SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY................................................................................................................ 32
SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY ............................................................................................... 33
SUCTION INLET DISASSEMBLY/ASSEMBLY ............................................................................................................................. 34
SKIRT GASKET REPLACEMENT ................................................................................................................................................. 35
HOPPER POSITION ADJUSTMENT............................................................................................................................................. 36
HOPPER DOOR CLOSING ACTUATOR ADJUSTMENT ............................................................................................................. 38
MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY .......................................................................................................... 40
SUCTION HOSE DISASSEMBLY/ASSEMBLY ............................................................................................................................. 42
WATER SYSTEM ........................................................................................................................................................... 43
DESCRIPTION .............................................................................................................................................................................. 43
TROUBLESHOOTING ................................................................................................................................................................... 44
HIGH PRESSURE PUMP REMOVAL/INSTALLATION ................................................................................................................. 45
HIGH-PRESSURE PUMP SAFETY SOLENOID VALVE DISASSEMBLY/ASSEMBLY ................................................................. 46
WATER LEVEL SENSOR DISASSEMBLY/ASSEMBLY ................................................................................................................ 47
NOZZLE AND FILTER CLEANING ................................................................................................................................................ 48
WATER FILTER CLEANING .......................................................................................................................................................... 50
WATER TANK EMPTYING ............................................................................................................................................................ 50
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STEERING SYSTEM ..................................................................................................................................................... 51
DESCRIPTION .............................................................................................................................................................................. 51
TROUBLESHOOTING ................................................................................................................................................................... 52
REAR AXLE TOE-IN ADJUSTMENT ............................................................................................................................................. 53
BRAKE SYSTEM ........................................................................................................................................................... 55
DESCRIPTION .............................................................................................................................................................................. 55
TROUBLESHOOTING ................................................................................................................................................................... 56
BRAKE FLUID LEVEL CHECK...................................................................................................................................................... 57
PARKING BRAKE CHECK AND ADJUSTMENT ........................................................................................................................... 58
PARKING BRAKE CONTROL CABLE REPLACEMENT............................................................................................................... 59
BRAKE SYSTEM CHECK ............................................................................................................................................................. 61
BRAKING MASSES REPLACEMENT ........................................................................................................................................... 61
BRAKE SYSTEM BLEEDING ........................................................................................................................................................ 62
DRIVE SYSTEM ............................................................................................................................................................. 63
DESCRIPTION .............................................................................................................................................................................. 63
TROUBLESHOOTING ................................................................................................................................................................... 64
TIRE PRESSURE CHECK ............................................................................................................................................................ 65
REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR ADJUSTMENT ......................... 66
REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY............................................................................................. 67
ENGINE START-UP INHIBITION SYSTEM CHECK AND ADJUSTMENT OF THE RELEVANT SENSOR .................................. 68
ENGINE START-UP INHIBITION SYSTEM SENSOR DISASSEMBLY/ASSEMBLY .................................................................... 69
HOPPER DOOR OPENING INHIBITION SYSTEM CHECK AND ADJUSTMENT OF THE RELEVANT SENSOR ..................... 70
ENGINE START-UP INHIBITION SYSTEM SENSOR DISASSEMBLY/ASSEMBLY .................................................................... 71
WHEEL REMOVAL/INSTALLATION .............................................................................................................................................. 71
DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY................................................................................................................ 72
DRIVE PEDAL CHECK AND ADJUSTMENT ................................................................................................................................ 73
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KUBOTA V1505T ENGINE ............................................................................................................................................ 75
DESCRIPTION .............................................................................................................................................................................. 75
TROUBLESHOOTING ................................................................................................................................................................... 76
ENGINE OIL LEVEL CHECK ......................................................................................................................................................... 77
ENGINE OIL CHANGE .................................................................................................................................................................. 77
ENGINE OIL FILTER CHANGE ..................................................................................................................................................... 78
ENGINE COOLANT LEVEL CHECK ............................................................................................................................................. 79
ENGINE AIR FILTER CLEANING .................................................................................................................................................. 80
FUEL FILTER REPLACEMENT ..................................................................................................................................................... 81
FUEL HOSE AND FITTING CHECK.............................................................................................................................................. 82
ALTERNATOR BELT TENSION CHECK ....................................................................................................................................... 83
ALTERNATOR BELT REPLACEMENT.......................................................................................................................................... 84
RADIATOR FIN CHECK AND CLEANING .................................................................................................................................... 85
ENGINE COOLANT LINE SLEEVE CHECK ................................................................................................................................. 86
ENGINE COOLANT CHANGE ...................................................................................................................................................... 87
ENGINE SPEED SENSOR REPLACEMENT ................................................................................................................................ 88
CLIMATE CONTROL SYSTEM ..................................................................................................................................... 89
DESCRIPTION .............................................................................................................................................................................. 89
TROUBLESHOOTING ................................................................................................................................................................... 90
COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine) ............................................................................................... 91
COMPRESSOR BELT REPLACEMENT ....................................................................................................................................... 92
COMPRESSOR REPLACEMENT ................................................................................................................................................. 93
AIR FILTER REPLACEMENT ........................................................................................................................................................ 94
OTHER SYSTEMS ......................................................................................................................................................... 95
NUT AND SCREW TIGHTENING AND LEAKAGE CHECK .......................................................................................................... 95
LUBRICATION ............................................................................................................................................................................... 96
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HYDRAULIC SYSTEM................................................................................................................................................... 97
DESCRIPTION .............................................................................................................................................................................. 97
COMPONENT LOCATION ............................................................................................................................................................ 98
HYDRAULIC DIAGRAM .............................................................................................................................................................. 100
TROUBLESHOOTING ................................................................................................................................................................. 102
HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK ........................................................................ 102
HYDRAULIC SYSTEM OIL LEVEL SENSOR REPLACEMENT ................................................................................................. 103
HYDRAULIC SYSTEM OIL AND SUCTION FILTER REPLACEMENT ....................................................................................... 104
HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT .................................................................................................... 106
DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT ............................................................................................................... 107
HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK.................................................................................................. 108
STEERING CYLINDER DISASSEMBLY/ASSEMBLY ................................................................................................................. 109
HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY................................................................................................................110
SUCTION FAN DISTRIBUTOR REMOVAL/INSTALLATION ........................................................................................................112
ACCESSORY SYSTEM DISTRIBUTOR REMOVAL/INSTALLATION ..........................................................................................113
ACCESSORY AND SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY ....................................................................................114
DRIVE SYSTEM PUMP DISASSEMBLY/ASSEMBLY..................................................................................................................116
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP ......................................................................117
HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY SYSTEM PUMP.........................................................119
HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP.......................................................................... 121
ELECTRICAL SYSTEM ............................................................................................................................................... 123
DESCRIPTION ............................................................................................................................................................................ 123
COMPONENT LOCATION .......................................................................................................................................................... 123
TROUBLESHOOTING ................................................................................................................................................................. 128
BATTERY FLUID LEVEL CHECK................................................................................................................................................ 129
POWER FUSE REPLACEMENT ................................................................................................................................................. 130
ACCESSORY FUSE REPLACEMENT ........................................................................................................................................ 131
POWER RELAY REPLACEMENT ............................................................................................................................................... 132
ACCESSORY RELAY REPLACEMENT ...................................................................................................................................... 133
CONTROL PANEL DISPLAY REPLACEMENT ........................................................................................................................... 134
LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT ............................................................................ 135
CONTROL PANEL DISPLAY FUNCTIONS ................................................................................................................................. 136
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INFORMAZIONI GENERALI
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 the Instructions for use Manual)
WARNING!
Before transporting the machine, make sure that:
– All doors and covers are closed.
– All moving parts are stopped.
– The ignition key is removed.
– The machine is securely fastened to the means of transport.
PUSHING OR TOWING THE MACHINE
WARNING!
When pushing or towing the machine, carefully follow the relevant instructions given in the Instructions for use
Manual. Failure to follow these instructions may cause damage to the machine.
OTHER AVAILABLE MANUALS
The following Manuals are available at Advance Literature Service Department:
–
RS 501 Spare Parts List – Advance Form Number 33019744
–
RS 501 Instructions for use Manual – Advance Form Number 33019745
–
RS 501 Wiring Diagram – Advance Form Number 33019500
SAFETY
The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary
precautions to safeguard people and property.
DANGER!
It indicates a dangerous situation with risk of death for the operator.
WARNING!
It indicates a potential risk of injury for people.
CAUTION!
It indicates a caution or a remark related to important or useful functions.
Pay careful attention to the paragraphs marked by this symbol.
NOTE
It indicates a remark related to important or useful functions.
CONSULTATION
It indicates that it is necessary to consult the Instructions for use Manual before performing any procedure.
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INFORMAZIONI GENERALI
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 authorized personnel only.
– Moreover, the operator must:
• Be 18 years or older
• Have a driving license
• Be in normal psycho-physical conditions
• Not be under the effect of substances that alters the nervous system (alcohol, psycopharmaceuticals,
drugs, etc.)
– Before performing any maintenance/repair procedure remove the ignition key, engage the parking brake and
disconnect the battery.
– Do not wear jewelry when working near electrical components.
– Do not work under the lifted machine without supporting it with safety stands.
– When working under open hoods/doors, make sure that they cannot be closed by accident.
– When performing maintenance procedures with the lifted hopper, apply the relevant safety rods.
– Do not operate the machine near toxic, dangerous, flammable and/or explosive powders, liquids or vapors.
– Be careful, fuel is highly flammable.
– Do not smoke or bring naked flames in the area where the machine is refueled or where the fuel is stored.
– Refuel outdoors or in a well-ventilated area, with the engine off.
– Do not fill the fuel tank to the top, but leave at least 1.6 in (4 cm) from the filler neck to allow the fuel to
expand.
– After refueling, check that the filler cap is tightly closed.
– If any fuel is spilled while refueling, clean up the affected area and allow the vapors to dissipate before
starting the engine.
– Avoid contact with skin and do not breathe in fuel vapors. Keep out of reach of children.
– Do not tilt the engine too much to avoid fuel spillage.
– During machine transportation, the fuel tank must not be full.
WARNING!
Carbon monoxide (CO) can cause brain damage or death.
The internal combustion engine of this machine can emit carbon monoxide.
Do not inhale exhaust gas fumes.
Only use indoors when adequate ventilation is provided, and when an assistant has been instructed to look
after you.
–
–
–
Do not lay any object on the engine.
Before working on the diesel engine turn it off. To prevent the engine from starting accidentally, disconnect
the battery negative terminal.
See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this
Manual.
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INFORMAZIONI GENERALI
WARNING!
– Carefully read all the instructions before performing any maintenance/repair procedure.
– Take all necessary precautions to prevent hair, jewelry and loose clothes from being caught by the machine
moving parts.
– Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using
compressed air or water gun.
– Avoid contact with battery acid, do not touch hot parts.
– Do not leave the machine unattended with the ignition key inserted and the parking brake disengaged.
– Do not remove or modify the plates affixed to the machine.
– To drive on public roads, the machine must follow local licensing requirements.
– The machine has been designed to be used as a sweeper, do not use it for different purposes.
– In case of part replacement, order ORIGINAL spare parts from an authorized Dealer or Retailer.
– The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries,
etc.), which are subject to standards that require disposal in special centers (see the Scrapping chapter in
the Instructions for use Manual).
– While the engine is running the silencer heats up. Do not touch the silencer to avoid serious scalding or fire.
– Do not run the engine if the oil level is low, to avoid damaging it seriously. Check the oil level with the engine
off and the machine on a level surface.
– Do not run the engine if the air filter is not installed, to avoid damaging it.
– The coolant line is pressurized; do not perform any check until the engine has cooled down and, even if the
engine is cold, the tank plug must be opened with extreme care.
– Only use original spare parts or parts of matching quality for the diesel engine. Using spare parts of lower
quality can seriously damage the engine.
– See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this
Manual.
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INFORMAZIONI GENERALI
TECHNICAL DATA
Dimensions and weights
Values
Machine length
122.4 in (3,110 mm)
Machine width (broom bristles not included)
52.8 in (1,340 mm)
Distance between front and rear wheels
57.9 in (1,470 mm)
Front wheel base
37.6 in (955 mm)
Rear wheel base
34.6 in (880 mm)
Machine height
78.6 in (1,997 mm)
Minimum distance from the ground (skirts not included)
3.5 in (90 mm)
Maximum front working angle
18°
Maximum dumping height
57.5 in (1,460 mm)
Front tires
R165/70 R14C 89R
Rear tires
R165/70 R14C 89R
Tire pressure
54 psi (3.75 Bar)
Side broom diameter
28,3 in (720 mm)
Total machine weight, in running condition (with 70 kg-operator)
3,748 lb (1,700 kg)
Hopper maximum load
1,168 lb (530 kg)
Performance data
Values
Maximum forward speed (for transport only)
12.4 mph (20 km/h)
Maximum working speed
7.4 mph (12 km/h)
Maximum reverse speed
5 mph (8 km/h)
Gradeability at full load during transport
22%
Minimum inner turning radius
96.8 in (2,460 mm)
Maximum side broom speed
80 rpm
Collection system
Suction
Cleaning width
63 in (1,600 mm)
Filtering system
Metallic net
Vibration level at the operator’s arms/body
2.1/1.2 in/s2 (0.652/0.371 m/s2)
Sound pressure level at workstation (ISO/EN3744) at maximum working speed
81 dB(A)
Certified sound power (2000/14/EC) at maximum working speed
110 dB(A)
Measured sound power (ISO/EN3744) at maximum working speed
107 dB(A)
Hopper capacity
132 USgal (500 liters)
Hopper maximum load
838 lb (380 kg)
Dust control system
By water
Dust control system tank total capacity (No. 2)
63.4 USgal (240 liters)
Lighting and signaling system
Road type
Transmission
Hydrostatic servoassisted
Steering system
On the rear axle, power assisted
Brake
Hydraulic
Parking brake
Mechanic
Controls
Hydraulic
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INFORMAZIONI GENERALI
V1505T diesel engine data (*)
Values
Make
KUBOTA
Type
V1505T
Cylinders
4
Maximum speed
2,800 rpm
Maximum working speed
2,200 rpm
Maximum power at 2,800 rpm
40.8 HP (30.6 kW)
Idle speed
1,100 rpm
Displacement
0.4 USgal (1,498 cm3)
Consumption while operating at 2,200 rpm (recommended speed)
4.6 L/h
Consumption during transport at 2,800 rpm (maximum speed)
4.3 L/h
Engine coolant
50% of AGIP antifreeze and 50% of water (**)
Engine oil
AGIP Sigma Turbo 15W/40 (***)
(*) For other diesel engine data/values, see the relevant Manual.
(**) See the coolant technical data and reference data tables below.
SPECIFICATIONS
REFERENCE DATA
Boiling point
°C/°F
170/338
CUNA NC 956-16 97
Boiling point in solution with 50% water
°C/°F
110/230
FF.SS cat. 002/132
Freezing point in solution with 50% water
°C/°F
-38/-36,4
ASTM D 1384
Color
/
Turquoise
blue
Density at 59 °F (15 °C)
kg/l
1,13
(***) See the engine oil technical data and reference data tables below.
SPECIFICATIONS
REFERENCE DATA
SAE QUALITY
/
15W40
ACEA E3
Viscosity at 212 °F (100 °C)
mm2/s
13,7
API Service CG-4/SG
Viscosity at 104 °F (40 °C)
mm2/s
100
CCMC D5, PD-2
Viscosity at 5 °F (-15 °C)
mm2/s
3.300
US Department of the Army MIL-L-2104 E
Viscosity index
/
138
US Department of the Army MIL-L-46152 E
Flash point COC
°C/°F
230/446
MACK EO-L
Pour point
°C/°F
-27/-16,6
MAN M 3275
Density at 59 °F (15 °C)
kg/l
0,885
Mercedes Benz 228.3
VOLVO VDS2
MTU typ 2
CAT TO-2
DEUTZ DQC-IV 05 level
DEUTZ DQC-II 05
ISOTTA FRASCHINI
ZF TE-ML-04 C
Refueling data
Values
Fuel tank capacity
8 USgal (30 liters)
Hydraulic system oil tank capacity
10.7 USgal (40.6 liters)
Hydraulic system capacity
15.3 USgal (58 liters)
Electrical system data
Values
System voltage
12 V
Starting battery
12 V – 80 Ah
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Hydraulic system data
Values
Maximum drive system pressure
3.626 psi (250 Bar)
Maximum accessory system pressure
1.740/2.901 psi (120/200 Bar)
Hydraulic system oil type (at ambient temperature above 50 °F (10 °C))
AGIP Arnica 46 (****)
NOTE
If the machine is to be used at ambient temperatures below 50 °F (10 °C), the oil should be replaced with equivalent oil
having a viscosity of 32 cSt. For temperatures below 32 °F (0 °C), use oil with lower viscosity.
(****)
See the hydraulic system oil technical data and reference data tables below.
TECHNICAL DATA
REFERENCE DATA
AGIP ARNICA
46
32
ISO-L-HV
45
32
ISO 11158
Viscosity at 104 °F (40 °C)
mm2/s
Viscosity at 100 °C
mm2/s
7,97
6,40
AFNOR NF E 48603 HV
Viscosity index
/
150
157
AISE 127
Flash point COC
°C/°F
215/419
202/395,6
ATOS Tab. P 002-0/I
Pour point
°C/°F
-36/-32,8
-36/-32,8
BS 4231 HSE
Density at 59 °F (15 °C)
kg/l
0,87
0,865
CETOP RP 91 H HV
COMMERCIAL HYDRAULICS
Danieli Standard 0.000.001 (AGIP ARNICA
22, 46, 68)
EATON VICKERS I-286-S3
EATON VICKERS M-2950
DIN 51524 t.3 HVLP
LAMB LANDIS-CINCINNATI P68, P69, P70
LINDE
PARKER HANNIFIN (DENISON) HF-0
REXROTH RE 90220-1/11.02
SAUER-DANFOSS 520L0463
Climate control system data (optional)
Values
Gas type
Reclin 134a
Gas quantity
1.8 lb (0.8 kg)
Camera kit data (optional)
Values
Make
Continental VDO -
Type
LCD 5" color monitor
Infrared color camera
ENVIRONMENTAL CONDITIONS
In the environment where the machine operates, there must not be any danger of explosion.
To avoid inhaling exhaust gas, the machine must be used only where there is a proper ventilation.
The machine operates properly (*) in the following environmental conditions:
–
Temperature: 14 °F to + 104 °F (-10 °C to 40 °C)
–
Humidity: 30% to 95%, not condensed
Store the machine indoor, in a clean and dry place, protected from bad weather conditions and with the following values:
–
Temperature: 33.8 °F to + 122 °F (1 °C to 50 °C)
–
Humidity: maximum 95%, not condensed
(*)
When using the machine at ambient temperatures between 14 °F and 32 °F (-10 °C and 0 °C), the dust control system cannot
be used; moreover the water tanks and the dust control system itself must be empty.
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INFORMAZIONI GENERALI
MAINTENANCE
The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.
WARNING!
See GENERAL INFORMATION and SAFETY paragraphs.
The following table provides the scheduled maintenance. The intervals shown may vary according to particular working conditions,
which are to be defined by the person in charge of the maintenance.
The instructions relating to the maintenance procedures given in the following table are described in the next paragraphs.
SCHEDULED MAINTENANCE TABLE
Maintenance
Running-in
period (after
the first 50
hours)
Every 10
Every Every Every Every Every Every Every Every
hours or
Long
100
200
400
500
800
900 1.200 2,400
before
periods
hours hours hours hours hours hours hours hours
use
Engine oil level check
Engine air filter cleaning
Engine radiator fin check and cleaning
Engine coolant level check
Battery fluid level check
Hydraulic system oil level and drain filter
efficiency check
Hydraulic system oil cooler fin check and
cleaning
Hopper, filter and suction hose cleaning, and
gasket check
Water nozzle and filter cleaning
Brake fluid level check
Reverse gear buzzer operation check
Disengaged parking brake buzzer operation
check
Operation check of the system for engine
start-up inhibition when the parking brake is
not engaged and the operator is not on the
driver’s seat.
Diesel engine start-up safety system check
(6)
Tire pressure check
Suction inlet and skirt height and operation
check
Side broom position check and adjustment
Engine oil change
(7)(8)
Dust control system water filter cleaning
Parking brake check
Alternator belt tension check
(7)
Climate control system compressor belt
tension check
(6)
Engine valve clearance check
(2)
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INFORMAZIONI GENERALI
Running-in
period (after
the first 50
hours)
Maintenance
Every 10
Every Every Every Every Every Every Every Every
hours or
Long
100
200
400
500
800
900 1.200 2,400
before
periods
hours hours hours hours hours hours hours hours
use
Engine turbocharger check
(2)
Diesel engine oil filter replacement
(7)(8)
Engine fuel filter replacement
(7)
Engine air filter replacement
Nut and screw tightening and leakage check
(6)
(6)
Lubrication
(6)
Engine coolant line sleeve check
(7)(6)
Drive system pump oil filter check
(6)
(6)
Hydraulic system oil drain filter replacement
(6)
(6)
Hydraulic system oil suction filter
replacement
(6)
(6)
Alternator belt replacement
(3)(6)
Cab air filter replacement
(1)
Injector check
(2)
Climate control system belt replacement
(6)
Engine coolant change
(3)(6)
Hydraulic system oil change
(3)(6)
Brake system check
(6)
Hydraulic system pump pressure check
(6)
Turbocharger check
(2)(5)
Injection pump check
(2)(5)
Minor engine overhaul
(2)(4)
Major engine overhaul
(2)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Or every 6 months
Maintenance to be performed by Kubota authorized Service Center
Or every two years
After 5,000 hours
After 3.000 hours
For the procedure see the Service Manual, at any Advance Service Center
Every year, if the machine is not frequently used
If a lower-quality oil is used, change it every 125 hours.
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INFORMAZIONI GENERALI
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.
Cab
Left door
Hopper
Diesel engine
Suction fan
Flashing light
Dust control system left tank
Front fixed wheels
Rear steering wheels
Right broom
Left broom
Suction inlet
Right door
Meter and control panel
Rear axle
Dust control system right tank
Rear suction pipe (*)
Left door
Left door fasteners
Right door
Right door fasteners
Cab right panel
Cab left panel
Right door handle
Left door handle
Hopper door
Open door support rod
Lifted hopper locking pins
Lifted hopper locking pins housing
Lifted hopper locking pins holes
Suction filter
Drain filter
Hydraulic system oil tank
Battery
Hydraulic system oil cooler
Suction inlet-to-hopper pipe
Fuel tank
Hopper manual lifting hand pump (to be used in case of
engine malfunction)
Hydraulic system oil drain filter
Hopper lifting device
Display scroll button
Left tank mounting screw
Working light switch
Right tank mounting screw
Front towing hook
Engine air filter
Fuel tank filler neck
Hopper top link
Left water tank filler plug
Right water tank filler plug
RS 501
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
Brake fluid tank
Windscreen wiper fluid tank
Windscreen wiper motor
Combination switch
Steering wheel adjusting lever
Drive pedal
Brake pedal
Steering wheel
Driver’s seat
Suction inlet and brooms control lever
Driver’s seat safety belt (*)
Hopper lifting/lowering lever
Debris suction turbine control lever
Cab heater hot water control knob
Diesel engine throttle lever
Parking brake lever
Broom dust control system nozzle valve
Suction inlet dust control system nozzle valve
Flap lifting control joystick
Lifted hopper warning light (red)
Hazard warning light switch
Dust control system switch
Cab blower switch
Windscreen wiper/washer switch
Climate control system switch (*)
Ignition key
Emergency push-button
Warning buzzer (it activates together with the warning
lights 87, 91, 93, 94)
Fuse box F3
Fuse box F2
Indicators and warning lights
Display (see the relevant functions)
Check engine warning light
Hydraulic system oil low level and hydraulic system fault
warning light
High beam indicator light
Running light indicator light
Charged battery indicator light (together with the indicator
light a buzzer activates with intermittent sound)
Parking brake indicator light (together with the indicator
light a buzzer activates with continuous sound)
Engine glow plug pre-heating warning light
Battery hygrometer
Battery release device
Fuse box F1
Engine coolant high temperature warning light (a buzzer
activates together with the warning light)
Engine oil pressure warning light (a buzzer activates
together with the warning light)
33019746(2)2010-03
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SERVICE MANUAL
INFORMAZIONI GENERALI
95.
96.
97.
98.
Turn signal indicator light
Hopper door opening/closing switch
Rear bumper
Diesel engine serial number/technical data plate (another
plate showing the same data as the plate affixed on the
diesel engine)(*)
99. High-pressure washing system hose with reel (*)
100. High-pressure water quick coupling (*)
101. Breather filter hood fasteners
102. Warning decal
103. Front skirt
104. Machine serial number
105. Hopper (dumping position)
106. Suction hose gasket
107. Hopper manual lifting hand pump lever
108. High-pressure water gun
109. Rear hood
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 inlet (on drive system pump)
116. Hydraulic system pressure inlet (at suction fan pump)
117. Hydraulic system pressure inlet (at accessory and steering
system pump)
118. Hopper door suction sealing gasket
119. Document holder
120. Hopper lifting/lowering lever safety flange
121. Suction inlet and broom lifting/lowering lever safety flange
122. Driver’s seat forward/backward adjustment lever
123. Ashtray
124. High-pressure water gun sprinkler nozzle
125. Cigarette lighter
126. Can holder
127. Broom speed adjuster (*)
128. Hydraulic system oil level indicator
129. Jack
130. Jack control lever
131. Jack mounting handwheel
132. Fluid drain hose
133. Rear camera (*)
134. Display (*)
135. Sun visor
136. Ceiling light
137. Ceiling light switch
138. Working light
139. Rear suction pipe cleaning blade
140. Rear hood fastening hooks
141. Water filter
142. ON/OFF switch (*)
143. Fire extinguisher (*)
144. High pressure pump safety solenoid valve (*)
(*)
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Optional
RS 501
SERVICE MANUAL
ENGLISH
INFORMAZIONI GENERALI
MACHINE NOMENCLATURE (Continues)
3
18
1
99
100
112
19
25
7
10
138
111
11
139
12
2
8
108
45
103
104
113
101
20
13
115
17
140
21
24
97
9
141
16
110
5
8
9
S341001
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SERVICE MANUAL
ENGLISH
INFORMAZIONI GENERALI
MACHINE NOMENCLATURE (Continues)
142
5
104
132
MODE
DIMMER
48 134
109
40
26
133
32
28
26
27
31
30
118
46
29
47
6
38
39
114
128
106
33
36
107
37
51
7
35
49
42
4
44
16
50
S341003
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SERVICE MANUAL
ENGLISH
INFORMAZIONI GENERALI
MACHINE NOMENCLATURE (Continues)
54c
58
119
54b
54a
143
54
59
61
65
55
66
60
64
62
68
67
63
69
53
57
121
120
52
56
124
98
22
122
129
116
!
Risk
e
achin
of m
t be
s mus
102
NING
injury
WAR d serious
r an
ve
tip-o
eed.
le sp
ssib
est po
slow
ly
rupt e
rn ab
in
ed
- Tu on incl er rais
pp
rn
- Tu with ho
rn
- Tu
e at
mad
p turn
Shar
t
Do no
ility.
l.
instab
anua
ses
’s M
increa
erator
pper
cline.
to Op
e ho
on in
in th
rding
pper
ight
acco
e ho
th we
sure
r rais
or wi
r pres
e
Neve
ai
in
cl
riate
on in
prop
ating
for ap
Oper
k tires
chec
larly
Regu
131
117
130
144
124
125
90
126
91
92
34
23
1
2
4
3
127
S341072
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SERVICE MANUAL
ENGLISH
INFORMAZIONI GENERALI
MACHINE NOMENCLATURE (Continues)
137
136
75
72
71
41
43
74
14
78
73
96
81
77
76
80
135
79
95
87
94
84
83
89
88
86
85
346798.05
ENG
rpm
70
%
100
105
82
S341074
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SERVICE MANUAL
ENGLISH
IMPIANTO DI SPAZZAMENTO
SWEEPING SYSTEM
DESCRIPTION
The sweeping system consists of:
A) Right broom
B) Left broom
C) Broom arms
The brooms (A) and (B) are supported by arms (C) which are fastened to the machine frame.
Broom rotation is activated by hydraulic motors.
For proper sweeping and conveyance of dust and debris towards the suction inlet:
–
Broom height and tilting must be properly adjusted;
–
Proper brooms must be used according to the type of ground to be cleaned. The following types are available:
• Polypropylene brooms
• Polypropylene and steel brooms
A
C
B
C
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SERVICE MANUAL
IMPIANTO DI SPAZZAMENTO
TROUBLESHOOTING
The brooms do not clean properly
Possible causes:
1. The brooms are not properly adjusted (adjust).
2. The broom speed is not correct (adjust).
The brooms do not rotate
Possible causes:
1. There are oil leaks from the hydraulic system hoses (replace the hoses).
2. The hydraulic motors are faulty (replace).
3. The accessory system hydraulic pump does not pressurize the oil in the circuit (check the hydraulic system oil pressure).
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ENGLISH
IMPIANTO DI SPAZZAMENTO
SIDE BROOM POSITION CHECK AND ADJUSTMENT
NOTE
Brooms of various hardness are available. This procedure is applicable to all types of brooms.
Check
1.
2.
3.
Check the side brooms for proper height and tilting, according to the following procedure:
• Drive the machine on a level ground.
• While keeping the machine stationary, fully lower the side brooms and allow them to rotate for a few seconds.
• Stop and lift the side brooms, then move the machine.
• Check that the size and orientation of the prints left by the side brooms are as follows:
– The right side broom must touch the ground along a circle arc (A) ranging from “11 o’clock” position to “4 o’clock”
position.
– The left side broom must touch the ground along a circle arc (B) ranging from “8 o’clock” position to “1 o’clock” position.
Adjust the broom height when the prints are out of specification, according to the following procedure.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Broom height adjustment
4.
5.
On both sides of the machine, operate on the tensioning self-locking nut (C) of the spring (D) and consider the following:
• To lower the broom, the nut (C) must be unscrewed;
• To lift the broom, the nut (C) must be screwed.
Perform step 1 again.
Broom forward tilting angle adjustment
6.
7.
On both sides of the machine, loosen the screws (E) and (F), then adjust the forward tilting angle (G).
When the adjustment is completed, tighten the screws (E) and (F).
Perform step 1 again.
Broom side tilting angle adjustment
8.
9.
On both sides of the machine, loosen the screws (I) and (L), then adjust the side tilting angle (H).
When the adjustment is completed, tighten the screws (I) and (L).
Perform step 1 again.
Broom side position adjustment
10. The purpose of this adjustment is to improve the side position of the brooms as to the suction inlet (12).
11. To perform the adjustment, loosen the nuts (J) and operate on the screw (K), thus changing the side position of the brooms.
12. When the side brooms are too worn out, the adjustment is not possible; replace the brooms according to the instructions in the
relevant paragraph.
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SERVICE MANUAL
IMPIANTO DI SPAZZAMENTO
SIDE BROOM POSITION CHECK AND ADJUSTMENT (Continues)
S301482
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ENGLISH
IMPIANTO DI SPAZZAMENTO
BROOM REPLACEMENT
NOTE
Brooms of various hardness are available. This procedure is applicable to all types of brooms.
CAUTION!
It is advisable to use protective gloves when cleaning the side brooms because there can be sharp debris
between the bristles.
1.
2.
3.
4.
5.
6.
7.
Lift the brooms and engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the centre screw (A), then remove the broom (B) to be replaced. Recover the key.
Remove the screws (D), then remove the flange (C).
Install the flange (C) 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.
B
B
D
B
B
C
A
S341005
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SERVICE MANUAL
IMPIANTO DI SPAZZAMENTO
BROOM SPEED ADJUSTMENT
Speed measurement
1.
2.
3.
4.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Connect a speed measurement indicator with a portable tachometer to the broom (10) or (11).
Start the machine and run the engine at maximum speed and set the broom speed adjuster (127) to maximum speed (as
shown in the Instructions for use Manual). In this condition, measure the broom speed with the portable tachometer. Turn off
the machine.
The broom speed must be: 80 rpm
If necessary, change the broom speed according to the following procedure.
Speed adjustment
5.
6.
7.
Remove the screws and the right panel (22) in the cab.
To change the broom speed, loosen the locknut (A) and turn the screw (B), then tighten the locknut (A).
Perform step 4 again.
B
A
S301510
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SERVICE MANUAL
ENGLISH
IMPIANTO DI RACCOLTA DETRITI E POLVERE
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)
O)
P)
Q)
Suction fan
Dust and debris suction filter
Hopper
Suction hose
Suction inlet
Skirt
Gasket between suction inlet and hopper
Hopper door
Hopper suction hole
Open door support rod
Lifted hopper locking pins
Lifted hopper locking pins housing
Lifted hopper locking pins holes
Air breather filter
Hoist
Top link
Hopper door suction sealing gasket
The suction fan (A), activated by an hydraulic motor, creates vacuum inside the hopper (C). The vacuum determines the suction
capacity of the suction inlet (E) through the suction hose (D).
The hopper (C) is made of steel.
It is fastened with two pins to a mechanic/hydraulic lifting system (O) (for hopper lifting) and to a dumping system (P) (for hopper
tilting). The door (H), which can be opened with an hydraulic control system, allows for debris discharging.
Both the door (H) and the suction hole (I) are equipped with gaskets, which allow the suction inlet (E) to reach the maximum suction
capacity.
Inside the hopper there are two stainless steel filters having the following functions:
–
The suction filter (B) retains dust and debris during fan suction phase, and makes them settle in the hopper;
–
The breather filter (N) retains dust and debris escaped from the suction filter, and does not allow them to be discharged
externally.
Both filters can be easily removed and cleaned.
To perform checks and maintenance procedures safely with the hopper lifted and the door opened, perform the following
procedures:
–
Turn the rod (J) to lock the door (H) in open position.
–
Remove the pins (K) from the housings (L) and place them into the holes (M) to lock the hopper (C) in lifted and dumped
position.
The suction inlet is made of sheet steel.
It is equipped with three wheels, which allow it to follow the pattern of the surface to be cleaned.
On its front side there is a skirt (F) that must be lifted to collect bulky debris.
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SERVICE MANUAL
ENGLISH
IMPIANTO DI RACCOLTA DETRITI E POLVERE
DESCRIPTION (Continues)
The suction fan (A), activated by an hydraulic motor, creates vacuum inside the hopper (C). The vacuum determines the suction
capacity of the suction inlet (E) through the suction hose (D).
The hopper (C) is made of steel and it is fastened with two pins to a mechanic/hydraulic lifting system (O) (for hopper lifting) and
to a dumping system (P) (for hopper tilting). The door (H), which can be opened with an electric control system, allows for debris
discharging. Both the door (H) and the suction hole (I) are equipped with gaskets, which allow the suction inlet (E) to reach the
maximum suction capacity.
Inside the hopper there are two stainless steel filters, which can be easily removed and cleaned. These have the following
functions:
–
The suction filter (B) retains dust and debris during fan suction phase, and makes them settle in the hopper;
–
The breather filter (N) retains dust and debris escaped from the suction filter, and does not allow them to be discharged
externally.
To perform checks and maintenance procedures safely with the hopper lifted and the door opened, perform the following
procedures:
–
Turn the rod (J) to lock the door (H) in open position.
–
Remove the pins (K) from the housings (L) and place them into the holes (M) to lock the hopper (C) in lifted and dumped
position.
The suction inlet is made of sheet steel and is equipped with two wheels, which allow it to follow the pattern of the surface to be
cleaned. On its front side there is a skirt (F) that must be lifted to collect bulky debris.
A
N
G
B
D
E
C
I
F
K
P
J
H
O
Q
K
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
S341006
TROUBLESHOOTING
The suction fan is noisy
Possible causes:
1. The motor is faulty (replace).
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 door gasket is broken (replace).
6. There is no pressure at the suction fan motor drive pump (adjust the pump pressure).
The suction fan does not turn
Possible causes:
1. The motor is faulty (replace).
2. The distributor is stuck (repair).
3. The pump is faulty (replace).
The suction inlet does not collect debris efficiently
Possible causes:
1. The suction inlet position is incorrect (check the suction inlet and skirt height and efficiency).
The skirt opening force is not sufficient
Possible causes:
1. The skirt opening pressure is incorrect (adjust).
The hopper does not lift/lower
Possible causes:
1. The distributor is stuck (repair).
2. The cylinder gaskets are worn (repair the cylinder).
The rear door does not open/close
Possible causes:
1. There is no voltage in the actuator (repair the electrical system).
2. The actuator is faulty (repair/adjust the actuator cams).
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SERVICE MANUAL
IMPIANTO DI RACCOLTA DETRITI E POLVERE
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.
2.
3.
Empty the hopper (3), drive the machine to a cleaning/washing appointed area, then engage the parking brake with the lever
(66).
Lift and dump the hopper (3), as shown in the Instructions for use Manual.
Install the door support rod (27).
Hopper cleaning
4.
5.
Clean the hopper (A) with pressurized water from a hydrocleaner (B).
Carefully check the suction sealing gasket (C) for integrity, and replace it if necessary.
Suction hose cleaning
6.
7.
Thoroughly clean the suction hose (D) inside, up to the suction inlet, with pressurized water.
Carefully check the suction sealing gasket (E) for integrity, and replace it if necessary.
Suction filter cleaning
8.
9.
10.
11.
12.
13.
Inside the hopper, remove the suction filter mounting handwheel (F).
Remove the suction filter (G).
Wash the deflector (H) and the fan (I) with pressurized water from a hydrocleaner (B); check that all fan sectors (J) are clean.
Clean the suction filter (G) with pressurized water from a hydrocleaner (B).
Install the suction filter (G) and secure it with the handwheel (F).
Remove the door support rod (27) and lower the hopper (3) according to the procedure shown in the Instructions for use
Manual.
14. Turn the ignition key (76) to OFF position and remove it.
Breather filter cleaning
15.
16.
17.
18.
19.
With a ladder and the help of an assistant, disengage the fasteners (K) of the breather filter hood (L).
Open the hood (L) and install the safety pin (M).
Remove the mounting screws (N), then remove the breather filter (O).
Clean the drain filter (O) with pressurized water from a hydrocleaner (B).
Install the breather filter and its hood performing steps from 15 to 17 in reverse order.
28
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK (Continues)
A
E
D
C
B
F
G
I
H
J
I
L
B
K
M
G
N
O
O
B
S341007
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK
Preliminary operations
1.
2.
3.
Engage the parking brake with the lever (66).
Lift the suction inlet (12), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Suction inlet wheel check
4.
Check that the three wheels (A) of the suction inlet are in good conditions and turn freely (they must not be bent/misshapen
because of bumps or excessive pressure, etc.). Check also that the rubber thickness (B) is not lower than some millimeters.
If necessary replace the wheels (A) (see the procedure in relevant paragraph).
Sliding panel check
5.
Check that the main sliding panel (C) and the front (D) and (E) and rear (H) sliding panels are in good conditions and that their
thickness (F) is not lower than 0.2 in (5 mm), otherwise replace them (see the procedure in the relevant paragraph).
It is important to replace the sliding panels (C), (D), (E), and (H) when they are not completely worn, to avoid damaging the
relevant mounting screws and making them difficult to remove.
Replace the sliding panels (C), (D), (E), and (H) as a unit, to avoid steps in the union areas (G), caused by different levels of
wear.
Suction inlet skirt and wheel adjustment check
6.
Check that the skirt (I) is integral and that it does not have excessive tears (J) or lacerations (K), which can affect the suction
inlet operation.
If necessary replace the skirt (I) (see the procedure in the relevant paragraph).
7. Drive the machine on a level ground and lower the suction inlet (12) according to the procedure shown in the Instructions for
use Manual.
8. Turn the ignition key (76) to OFF position and remove it.
9. Check that the distance (L) of the skirt from the ground is not bigger than 0.39 in (1 cm). Greater distances can affect the
suction inlet operation.
If necessary replace the skirt (K) (see the procedure in the relevant paragraph).
10. Also check that, when the three wheels (A) contact the ground, the sliding panels (C), (D), (E), and (H) do not touch the
ground, otherwise the wheels (A) must be replaced to avoid an excessive wear of the sliding panels (for wheel replacement
procedure, see the relevant paragraph).
11. Start the machine according to the procedure shown in the Instructions for use Manual, then press the switch (69) and check
that the skirt (I) lifts freely. Check that it lifts also when a force of some kg is applied (simulating to move bottles or other heavy
objects that must then be collected). If necessary, adjust the opening force of the skirt (I) according to the following procedure:
• Turn off the machine.
• Remove the screws and the right panel (22) in the cab.
• Loosen the control valve locknut (N) and turn the screw (O) as necessary, reminding that:
– The opening force decreases by loosening the screw;
– The opening force increases by tightening the screw.
• When the adjustment is completed, tighten the locknut (N).
• Install the right panel (22) in the cab and tighten the screws.
Reset
12. Assemble the components in the reverse order of disassembly.
30
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
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
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
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.
2.
3.
4.
5.
6.
Engage the parking brake with the lever (66).
Lift the suction inlet (12), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
On both sides of the machine, loosen the screws (E) and (F), then remove the front wheels (A) and (B).
Install the new front wheels (A) and (B) and fasten them with the screws (E) and (F).
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
Front wheels (A) and (B), and rear wheel (C) removal/installation
7.
Place the machine on the appropriate hoisting system (if present) and lift it.
If the hoisting system is not available, remove the suction inlet assembly (D) (see the procedure in the relevant paragraph).
8. Remove the screws (E), (F) and (G), then remove the wheels (A), (B) and (C).
9. Install the new wheels (A), (B) and (C) and fasten them with the screws (E), (F) and (G).
10. Perform step 1 again.
11. If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
E
A
C
D
G
B
F
S301485
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
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) as shown in the relevant paragraph. See the following disassembling procedures.
1.
2.
3.
4.
5.
6.
Place the machine on the appropriate hoisting system (if present) and lift it.
If the hoisting system is not available, remove the suction inlet assembly (D) (see the procedure in the relevant paragraph).
Remove the mounting screws (A), and (B), then remove the sliding panels (C), (D), and (E).
Install the new sliding panels (C), (D), and (E) and fasten them with the screws (A), and (B).
Also check that, when the wheels (F) contact the ground, the sliding panels (C), (D), and (E) do not touch the ground,
otherwise the wheels (F) must be replaced to avoid an excessive wear of the sliding panels (for wheel replacement procedure,
see the relevant paragraph).
Perform step 1 again.
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
F
E
D
B
F
A
C
C
A
F
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SUCTION INLET DISASSEMBLY/ASSEMBLY
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the side brooms (see the procedure in the relevant paragraph).
Lower the suction inlet (12), as shown in the Instructions for use Manual.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Disconnect the hydraulic system hoses (A) and (B) from the suction inlet (C) and plug them.
Disconnect the dust control system water hose (D).
Remove the nuts (E) and pins (F).
Move the suction inlet (C) forward, and loosen the suction hose clamp (G).
Disconnect the suction hose (H) from the suction inlet.
Remove the suction inlet (C).
Assembly
11. Assemble the components in the reverse order of disassembly.
If necessary, perform the suction inlet and skirt height and operation check (see the procedure in the relevant paragraph).
F
H
B
A
G
D
E
E
F
C
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IMPIANTO DI RACCOLTA DETRITI E POLVERE
SKIRT GASKET REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
Lower the suction inlet (12), as shown in the Instructions for use 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 gasket (D).
Install the new skirt gasket (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 Instructions for use Manual.
C
D
A
B
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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 doors (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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Loosen the locknut (A). Perform the same procedure on the left side.
Insert a lever into the hole (C), then turn the top link lever (B) as necessary. Perform the same procedure on the left side.
Remove the locking pins (28) and place them into the holes (29).
Lower the hopper (3), according to the procedure shown in the Instructions for use Manual, and check that the profile (D)
match the frame profile (E) on both right and left side.
If necessary, perform steps 4, 5, 6, 8, 9 and 10 again.
Then perform steps 3, 4, 5 and tighten the locknuts (A).
Lower the hopper (3), according to the procedure shown in the Instructions for use Manual, and check that the hopper suction
hole (F) match the suction hose gasket (G). If necessary, adjust the position of the suction hose (H) according to the procedure
shown in the following steps.
Perform steps 4, 5 and 6 again.
Loosen the left and right side screws (I) (J) and (L), then adjust the position of the suction hose (H). Tighten the left and right
side screws (I) (J) and (L).
Lower the hopper (3), according to the procedure shown in the Instructions for use Manual, and check that the hopper suction
hole (F) match the suction hose gasket (G).
Close the right and left doors (20) and (18) by engaging the fasteners (21) and (19) with the supplied key.
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HOPPER POSITION ADJUSTMENT (Continues)
D
A
B
E
C
G
F
I
H
J
L
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HOPPER DOOR CLOSING ACTUATOR ADJUSTMENT
Preliminary operations
1.
2.
3.
4.
5.
6.
7.
Empty the hopper (3), according to the procedure shown in the Instructions for use Manual.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Remove the screws (A), then remove the cover (B) and the gasket (C) of the actuator (R), under the rear side of the hopper.
Door safety hook closing
8.
According to the procedure shown in the Instructions for use Manual, turn the safety hook (D) of the door (E) to closing
position (as shown in the figure); in this condition, loosen the security dowel (F) of the cam (G), and then turn the cam until the
microswitch (H) activates.
Open safety hook warning light adjustment
9.
When the safety hook (D) of the door (E) is turned to closing position (as shown in the figure), loosen the security dowel (I) of
the cam (J), and turn the cam until the corner (K) causes the microswitch (L) to activate and the warning light to turn off.
Door safety hook opening end-of-stroke adjustment
10. According to the procedure shown in the Instructions for use Manual, turn the safety hook (D) of the door (E) to the opening
end-of-stroke; in this condition, loosen the security dowel of the cam (N), and then turn the cam until the microswitch (O)
activates.
NOTE
To maximize cam adjustment consider the following:
– The cam turns in the direction shown by the arrow (P) when the hook (D) opens;
– The cam turns in the direction shown by the arrow (Q) when the hook (D) closes.
11. To check the cam proper adjustment, open and close the hook (D) several times.
Reset
12. Perform steps 3 to 7 in the reverse order.
C
B
R
A
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HOPPER DOOR CLOSING ACTUATOR ADJUSTMENT (Continues)
P
Q
G
F
I
J
N
H
L
O
D
E
K
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MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
With a ladder and the help of an assistant, disengage the fasteners (A) of the breather filter hood (B).
Open the hood (B) and install the safety pin (C).
Remove the mounting screws (D), then remove the breather filter (E) by dumping the hood (B).
Disconnect the hoses joints (G) and (H) from the suction fan motor (I).
Remove the mounting nuts (J) of the flange (M).
With an appropriate hoisting system, remove the suction fan motor assembly (K) by removing the silicone along the perimeter
(L) of the flange (M), then sling the assembly (K) by placing a rope around the motor (I) and the fittings (N).
9. At the workbench, remove the screw (O) and the fan (P).
10. Remove the nuts (Q) from the screws (F).
11. Remove the motor (I) from the flange (M).
Assembly
12. Assemble the components in the reverse order of disassembly and note the following:
• Remove the silicone along the perimeter (L) of the flange (M) and from the flange housing on the hopper.
• Apply new silicone along the perimeter (L) of the flange (M).
D
E
B
A
C
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MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY (Continues)
Q
N
H
N
G
J
K
M
L
F
P
O
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SUCTION HOSE DISASSEMBLY/ASSEMBLY
Preliminary operations
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left doors (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Disassembly
7.
8.
9.
Loosen the clamp (A) and disconnect the suction hose (B) from the suction inlet (C).
Loosen the left and right side mounting screws (D) of the suction hose upper end (E).
Remove the suction hose (F) by pulling it upwards.
Assembly
10. Assemble the components in the reverse order of disassembly and note the following:
• For a easier installation of the suction hose (B) into the suction inlet (C), apply a thin coat of grease on the sliding parts.
B
D
A
F
E
C
D
D
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IMPIANTO IDRICO
WATER 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) Tank drain plugs
H) Water level sensor
I)
Nozzle pump
J) Valves
K) Rear suction pipe nozzle
L) Opening valve
The water gun connected to the dust control system consists of:
M) Pressure gauge
N) Water gun pump
O) Quick coupling
P) Water gun
Q) Hose
R) Reel
O
C
A
P
L
Q
K
R
M
D
E
E
D
J
J
B
N
F
G
G
I
A
H
C
A
B
F
I
J
E
J
L
E
N
K
D
D
O
P
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TROUBLESHOOTING
No water from the nozzles
Possible causes:
1. The water filter is clogged (clean/replace).
2. The nozzles are clogged (clean).
3. Run out of water (fill in).
4. The water pump is off (press the switch to turn it on).
No water to the nozzles
Possible causes:
1. The water pump relay is burned (replace).
2. The pump does not work (repair/replace).
3. There is an open in the fuse (replace).
4. The engine is off (start the engine).
5. The display enabling is not present (check the connections/replace).
6. The speed sensor signal is not present (check the connections/replace).
7. The water pump does not work (replace).
8. The water pump is off (press the switch to turn it on).
9. The safety control unit fuse is open (replace).
The water pump does not stop
Possible causes:
1. The water pump relay is faulty (replace).
2. The water tank level sensor is stuck (replace).
3. The display enabling is short circuited (check the connections/replace).
4. The water pump switch is damaged (replace).
The high-pressure washing system water pump stops automatically
Possible causes:
1. The water level in the dust control system tanks is low (fill-in).
2. The water tank level sensor is short-circuited (replace).
3. The high-pressure pump safety valve is faulty (replace).
The high-pressure washing system water pump does not stop automatically when the water level is low
Possible causes:
1. The water tank level sensor is open (replace).
2. The high-pressure pump safety valve is faulty (replace).
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HIGH PRESSURE PUMP REMOVAL/INSTALLATION
High-pressure pump pressure check:
1.
2.
3.
4.
Use the high-pressure washing system as shown in the Instructions for use Manual.
If the water gun (108) does not work properly, check its operating pressure with the pressure gauge (112). The pressure must
be 2,610 psi (180 Bar) approximately.
If the pressure is normal, the problem is in the water gun (108).
If the pressure is irregular, check the operating pressure of the high-pressure pump according to the procedure shown in the
paragraph “Pressure check at the suction fan pump”.
• If the pressure is irregular the accessory pump and suction fan must be checked/replaced, as shown in the relevant
paragraph.
• If the pressure is regular the high-pressure pump must be checked/replaced as described below.
CAUTION!
The fault can be caused by the flow regulator (K) of the high-pressure pump.
This component can be replaced separately.
High pressure pump removal/installation:
1.
2.
3.
4.
5.
6.
Lift the hopper as shown in the Instructions for use Manual.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Insert the safety pins as shown in the Instructions for use Manual.
Disconnect the water hoses (B and C) from the high-pressure pump (A) and plug them immediately.
Disconnect the hydraulic hoses (D and E) from the high-pressure pump (A) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
7.
Remove the screws (F) and recover the washer (G) to be reused when reassembling. Then remove the high-pressure pump
(A).
8. At the workbench, unscrew the fittings (H, I and J) from the high-pressure pump (A).
9. Assemble the components in the reverse order of disassembly.
10. Check the hydraulic system oil level (see the procedure in the relevant paragraph).
E
F
I
H
D
K
A
G
A
C
J
B
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HIGH-PRESSURE PUMP SAFETY SOLENOID VALVE DISASSEMBLY/ASSEMBLY
Sub-tank water level sensor disassembly/assembly:
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 and the right panel (22) on the right side of the cab.
Disconnect the electrical connection (A) from the solenoid valve (B).
Disconnect the hydraulic hoses (C e D) from the solenoid valve (B) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
6.
7.
8.
9.
10.
Remove the through bolt (E) and disconnect the hydraulic hose (F) from the solenoid valve (B) and plug it.
Remove the screws (J) and the nuts (K), then remove the solenoid valve (B).
At the workbench, unscrew the fittings (G, H and I) from the solenoid valve (B).
Assemble the components in the reverse order of disassembly.
Check the hydraulic system oil level (see the procedure in the relevant paragraph).
K
B
A
C
D
F
J
E
G
I
H
B
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WATER LEVEL SENSOR DISASSEMBLY/ASSEMBLY
Sub-tank water level sensor disassembly/assembly:
1.
2.
3.
4.
5.
6.
7.
8.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Empty the dust control system water tanks as shown in the “Water tank emptying” paragraph.
Open the right water tank (16) by loosening the mounting screw (44). If necessary, disconnect the fastener.
Locate the water tank level sensor (A).
Disconnect the electrical connection (B).
Loosen the nut (C) to release the expansion ring nut (D), then remove the sensor (F).
Assemble the components in the reverse order of disassembly and note the following:
• Place the sensor (F) on the tank housing so that the float (E) activates by turning upwards, as shown in the figure.
E
D
F
C
B
A
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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.
2.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Cleaning of nozzles and filters on brooms
3.
4.
5.
Unscrew the ring nuts (A).
Clean the nozzles (B) and filters (C) with compressed air. Remove calcium deposits. If necessary, replace the filters (C).
Install the filters and nozzles, and secure them with the ring nuts. Nozzle holes must be directed down when tightening.
Cleaning of nozzles inside the suction inlet
6.
7.
8.
On both sides of the suction inlet (D), remove the screws (E) together with the nozzles (F).
Clean the nozzles (F) and screws (E) with compressed air. Remove calcium deposits.
Assemble the components in the reverse order of disassembly.
Cleaning of nozzle and filter in the rear suction pipe
9. Remove the screw (G), the nozzle (H) and the filter (I).
10. Clean the nozzle (H) and filter (I) with compressed air. Remove calcium deposits. If necessary, replace the filter (I).
11. Assemble the components in the reverse order of disassembly.
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NOZZLE AND FILTER CLEANING (Continues)
C
A
B
A
E
E
D
F
F
H
I
G
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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.
2.
3.
4.
5.
6.
Turn the ignition key (76) to OFF position and remove it.
Engage the parking brake with the lever (66).
In the area under the rear bumper (97), remove the water filter cover (A) together with the filter element (B).
Separate the filter element (B) from the cover (A), then wash and clean it. If necessary, replace the filter element (B).
Install the filter element (B) and the cover (A).
If necessary, fill the water tanks.
B
A
A
S341014
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).
B
A
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STERZO
STEERING SYSTEM
DESCRIPTION
The steering wheel activates the power steering which controls a double-effect hydraulic cylinder that operates on the rear wheels
assembled on a steering axle.
The steering system consists of:
A) Hydraulic pump
B) Priority valve
C) Power steering
D) Rear wheel control hydraulic cylinder
E) Hydraulic system oil tank
F) Hydraulic system hoses
E
D
C
B
A
F
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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 power steering is faulty (replace).
2. The priority valve is faulty (replace).
3. The rear wheel hydraulic control cylinder is faulty (replace).
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REAR AXLE TOE-IN ADJUSTMENT
1.
2.
3.
4.
5.
Drive the machine on a solid and level ground and keep the rear wheels (A) in a straightforward position, then engage the
parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Prepare two metal plates (B) to be used as reference lines. The plates must be a little longer than the wheel diameter.
Place the plates (B) on the external surface of the wheels (A), at the centre of the wheels and parallel to the ground, as shown
in the figure.
Do not place the plates (B) where the tire surface is irregular.
Keeping the plates (B) in the above-mentioned position, check that the distances (E) and (F), measured on the front and on
the back of the wheels (A), are the same. A maximum difference of 0.16 in (4 mm) between the two distances is admitted. If
necessary, adjust the distances by loosening the nuts (D) and turning the tie rods (C). Then tighten the nuts (D).
B
A
F
D
C
E
C
D
B
A
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STERZO
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IMPIANTO FRENI
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) Brake cylinders
E) Pipes
F) Drum brakes
The parking brake is mechanic, manually controlled, and actuates on the drum brakes of the front wheels.
The parking brake consists of:
G) Drum brakes
H) Parking brake lever
I)
Bracket
J) Control cable
G
C
A
H
B
E
E
E
I
I
D
D
F
F
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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 (replace).
3. There is air in the system (bleed).
4. The drum brake cylinder is faulty (replace).
5. The braking masses are worn or greasy (replace).
The parking brake is not efficient
Possible causes:
1. The brake is misadjusted (adjust).
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BRAKE FLUID LEVEL CHECK
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 door (20).
Check that the fluid level in the tank (A) is approximately at 0.4 in (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 door (20).
A
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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.
3.
4.
5.
6.
7.
8.
9.
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
10. Operating under the parking brake lever (66), adjust the brake control cables according to the following procedure depending
on the type of adjustment (same adjustment for both wheels, or adjustment of one wheel only if braking is unbalanced):
• To adjust both cables (I) in the same way: loosen the locknuts (D), move the bracket (B) as necessary along the tie rod (C),
then tighten the locknuts (D); or loosen the locknuts (G) and (H), give the tie rods (E) and (F) the same number of turns,
then tighten the locknuts (G) and (H).
• To adjust just one of the cables (I): loosen the locknuts (G) or (H), turn the tie rods (E) or (F), then tighten the locknuts (G)
or (H).
11. Perform steps 4, 5, 6, 7 and 9 in the reverse order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
I
I
E
B
C
F
G
H
D
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IMPIANTO FRENI
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (41).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Operating under the parking brake lever (66), unscrew the locknuts (C) and (D), disconnect the control cable (E) or (B) and
recover the relevant spring (A).
Remove the front wheel (see the procedure in the relevant paragraph).
Place safety stands under the machine side sill.
Remove the screw (H) and the screws (I), then remove the washer (J).
Through the hole (F), turn the inner roller so that the shoes withdraw. When the shows are withdrawn, the drum can turn freely.
Place the puller (G) on the drum (K) and match the puller holes with the drum columns (Q).
Fasten the puller (G) with the wheel mounting nuts (R).
Remove the drum (K) by slightly hammering the screw (S).
Remove the three springs (L).
Remove the shoe retaining springs (M).
Remove the shoes (N) by disengaging the parking brake control cable (O) from the lever (P).
Perform steps 3 to 6 and 8 to 19 in the reverse order.
Adjust the parking brake (see the procedure in the relevant paragraph).
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
E
B
D
A
C
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PARKING BRAKE CONTROL CABLE REPLACEMENT (Continues)
J
H
F
I
K
Q
S
G
Q
R
L
P
O
M
M
N
N
L
L
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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).
BRAKING MASSES REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
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).
Through the hole (J), turn the inner roller so that the shoes withdraw. When the shows are withdrawn, the drum can turn freely.
Place the puller (L) on the drum (D) and match the puller holes with the drum columns (K).
Fasten the puller (L) with the wheel mounting nuts (M).
Remove the drum (D) by slightly hammering the screw (N).
Remove the three springs (E).
Remove the shoe retaining springs (F).
Remove the shoes (G) together with the braking masses, by disengaging the parking brake control cable (H) from the lever (I).
Perform steps 1 to 10 in the reverse order.
C
A B
D
K
J
N
M
L
K
E
I
H
F
F
G
G
E
E
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BRAKE SYSTEM BLEEDING
WARNING!
Brake system bleeding must be always performed with the system opened.
It must also be performed on both front wheels.
1.
2.
3.
4.
5.
6.
7.
Check the brake fluid level (see the procedure in the relevant paragraph).
Remove one of the front wheels (see the procedure in the relevant paragraph).
Place safety stands under the machine side sill, on the side where the wheel has been removed.
Remove the brake system bleed valve plug (A) and connect the pipe (B) to bleed the fluid.
Press the brake pedal (57) until the pedal resistance increases. In this condition, keep the pedal pressed and unscrew the
valve (A) slightly. Let the oil and air bleed from the pipe (B) into the container (C) until no more air comes out, but oil only. Then
screw down the valve (A) and release the brake pedal (57).
Perform steps 2 to 4 in the reverse order.
Bleed the brake system also on the other front wheel, by performing steps from 2 to 6 again.
B
A
C
OIL
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DRIVE SYSTEM
DESCRIPTION
The drive pedal controls two independent drive system hydraulic motors applied to the front wheels.
Front and rear wheels are pneumatic.
The drive system consists of:
A) Drive pedal
B) Right drive system motor
C) Left drive system motor
D) Drive system pump
E) Hydraulic system oil tank
F) Hoses
E
B
A
C
D
F
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TROUBLESHOOTING
The machine stability is reduced
Possible causes:
1. The tires are not properly inflated (check tire pressure).
The rear axle is noisy
Possible causes:
1. The wheel bearings are worn (replace).
The machine power is reduced
Possible causes:
1. The drive system motors are worn (replace).
2. The drive pedal is faulty (replace).
3. The drive system pump power decreases (check the oil pressure at the drive system pump).
The machine does not move
Possible causes:
1. The drive system pump deactivation screw for machine pushing/towing is unscrewed (screw down).
2. There are oil leaks from the hydraulic system (repair).
3. The drive system pump is broken (replace).
4. The drive system motor is broken (replace).
The machine moves even if the drive pedal is released
Possible causes:
1. The drive pedal is misadjusted (adjust).
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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:
54 psi (3.75 Bar)
• Rear tires:
54 psi (3.75 Bar)
5
6
3,
5
4
3
80
7
60
40
0
2,5
10
14
0
bar
9
1
20
120
1,5
2
8
psi
0
10
1.
2.
3.
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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
1.
2.
3.
4.
5.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
Check that the distance between the sensor surface (A) and the bracket (E) is within 0.59 and 0.98 in (1.5 and 2.5 mm). When
checking, move the drive pedal (F) towards the bracket (E) to cancel the drive pedal end play.
If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed,
tighten the nuts (G) and (H).
Perform step 1 again.
F
A
C
D
G
E
B
E
H
G
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REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY
Disassembly
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.
Cut the cable clamp (A) under the right side of the cab.
Disconnect the reverse gear buzzer activation sensor connector (B).
Remove the four mounting screws (D) of the drive pedal (E).
Slightly lift the drive pedal (E) and remove the mounting nut (F) of the sensor (C).
Remove the sensor (C), the harness (G) and the connector.
Assembly
8.
9.
Assemble the components in the reverse order of disassembly.
Adjust the reverse gear buzzer activation sensor (see the procedure in the relevant paragraph).
A
A
B
F
E
C
G
D
C
D
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ENGINE START-UP INHIBITION SYSTEM CHECK AND ADJUSTMENT OF THE RELEVANT SENSOR
Check
1.
Check that, when one of the two sensors located in the lower part of the pedal, does not read (the sensor LED is off), the
engine does not start.
If necessary, adjust the relevant sensor according to the following procedure.
Adjustment
1.
2.
3.
4.
5.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
Check that the distance between the sensor surface (A) and the bracket (E) is within 0.59 and 0.98 in (1.5 and 2.5 mm). When
checking, move the drive pedal (F) towards the bracket (E) to cancel the drive pedal end play.
If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed,
tighten the nuts (G) and (H).
Perform step 1 again.
F
A
C
D
G
E
B
E
H
G
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ENGINE START-UP INHIBITION SYSTEM SENSOR DISASSEMBLY/ASSEMBLY
Disassembly
1.
Proceed as shown in the “Reverse gear buzzer sensor disassembly/assembly” paragraph.
Assembly
2.
Proceed as shown in the “Reverse gear buzzer sensor disassembly/assembly” paragraph.
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HOPPER DOOR OPENING INHIBITION SYSTEM CHECK AND ADJUSTMENT OF THE RELEVANT
SENSOR
Check
1.
Check that, when one of the two sensors located in the lower part of the pedal, does not read (the sensor LED is off), the
hopper door (26) does not open.
If necessary, adjust the relevant sensor according to the following procedure.
Adjustment
1.
2.
3.
4.
5.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Check that the surface (A) of the sensor (B) is flush with the surface (C) of the drive pedal.
If necessary, loosen the sensor mounting nut (D) and adjust the sensor position. When the adjustment is completed, tighten
the nut (D).
Check that the distance between the sensor surface (A) and the bracket (E) is within 0.59 and 0.98 in (1.5 and 2.5 mm). When
checking, move the drive pedal (F) towards the bracket (E) to cancel the drive pedal end play.
If necessary, loosen the nuts (G) and the nut (H), and adjust the position of the bracket (E). When the adjustment is completed,
tighten the nuts (G) and (H).
Perform step 1 again.
F
A
C
D
G
E
B
E
H
G
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ENGINE START-UP INHIBITION SYSTEM SENSOR DISASSEMBLY/ASSEMBLY
Disassembly
1.
Proceed as shown in the “Reverse gear buzzer sensor disassembly/assembly” paragraph.
Assembly
2.
Proceed as shown in the “Reverse gear buzzer sensor disassembly/assembly” paragraph.
WHEEL REMOVAL/INSTALLATION
Preliminary operations
1.
2.
3.
4.
Turn the ignition key (76) to OFF position and remove it.
Engage the parking brake with the lever (66).
Check that the machine cannot move with one wheel lifted (the parking brake operates only on the front wheels). If necessary
keep the machine stationary by placing wedges on the wheels contacting the ground.
Remove the wheel according to the following procedure.
Rear wheel removal/installation
5.
6.
7.
8.
Place the jack (A) (not equipped) under the relevant housing (B) in the rear axle (C), as shown in the figure.
Carefully activate the jack (A) with the lever (E) and lift the wheel (D) until it is slightly detached from the ground.
Remove the mounting nuts, then remove the wheel (D).
Install the wheel (D) by performing steps from 5 to 7 in the reverse order.
Wheel mounting nut tightening torque: 295 lb·ft (400 N·m)
Front wheel removal/installation
9.
Place the jack (A) (not equipped) under the relevant housing (G) on the machine side sill, in front of the wheel (H), as shown in
the figure.
10. Carefully activate the jack (A) with the lever (E) and lift the wheel (H) until it is slightly detached from the ground.
11. Remove the mounting nuts, then remove the wheel.
12. Install the wheel by performing steps from 9 to 11 in the reverse order.
Wheel mounting nut tightening torque: 295 lb·ft (400 N·m)
WARNING!
Use a suitable jack with a minimum lifting capacity of 4,409 lb (2 ton).
G
D
A
C
B
E
F
A
E
H
F
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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 (K) under the machine side sill, on
the side where the wheel has been removed.
Disconnect the brake system pipe (A) from the brake assembly (B) and plug it immediately.
Remove the right or left nut (E), then disconnect the parking brake control cable (C) from the bracket (D).
Disconnect the hoses (F) and the hoses (H) from the drive system motor (J) and plug them immediately. The hoses (H) are on
the right drive wheel only.
Remove the five mounting screws (G), then remove the drive system motor (J) together with the brake assembly (B).
Assemble the components in the reverse order of disassembly and note the following:
• Before assembling the wheel, bleed the brake system (see the procedure in the relevant paragraph).
Check the brake system (see the procedure in the relevant paragraph).
Adjust the parking brake (see the procedure in the relevant paragraph).
A
C
K
I
B
J
F
D
F
F
B
H
G
H
E
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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.
4.
5.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position.
Check that the drive pedal (56) turns freely on its shaft and that it does not bind/slow down, which may prevent the pedal from
resuming the neutral position.
If necessary, remove the possible cause for binding/slowing down, then repeat step 1.
If the problem persists, adjust the drive system pump as shown below.
Drive system pump adjustment
6.
7.
8.
9.
10.
11.
12.
13.
14.
Disengage the parking brake with the lever (66).
Stop the left front wheel with two wedges (A).
Remove the right front wheel as shown in the relevant paragraph.
Place safety stands (B) under the machine side sill, on the side where the wheel has been removed.
Lift the hopper (3) for 7.9 in (20 cm), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (43).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
15. Turn on the diesel engine with care.
WARNING!
When the diesel engine is running, the wheel hub (C) can be rotating.
16. Check that the machine is in the following conditions:
• Diesel engine is running
• Drive pedal (56) is not pressed
• Brakes and parking brake are not activated
In these conditions, operating on the drive system pump (F), loosen the locknut (D) then turn the threaded dowel (E) clockwise
or counter-clockwise, until the hub (C) stops.
Tighten the locknut (D).
17. Engage the parking brake with the lever (66).
18. Turn the ignition key (76) to OFF position.
19. Perform steps 6 to 12 in the reverse order.
20. Perform step 1 again.
21. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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DRIVE PEDAL CHECK AND ADJUSTMENT (Continues)
A
A
F
E
D
B
C
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MOTORE KUBOTA V1505T
KUBOTA V1505T ENGINE
DESCRIPTION
The machine is equipped with a four-cylinder diesel engine. The engine activates the hydraulic system pumps, the 12 V alternator
(that charges the electrical system) and the climate control system compressor.
For diesel engine data see the “Technical data” chapter and the Diesel Engine Manual.
–
The hydraulic system pumps connected to the engine are the following:
A) Accessory and power steering pump (10 cc)
B) Suction fan pump (14 cc)
C) Drive system pump (21 cc)
–
When the machine is equipped with the climate control system, the following components are installed on the engine:
D) Compressor
E) Compressor pulley
F) Drive belt
–
The alternator (G) is driven by the belt (H) through the pulley (I).
A
B
C
I
G
H
D
F
E
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TROUBLESHOOTING
The diesel engine does not start
Possible causes:
1. The drive pedal is pressed (release).
2. The sensor for engine start-up inhibition is misadjusted/broken (adjust/replace).
NOTE
For diesel engine complete troubleshooting, see the relevant Manual.
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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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (49) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
10.
11.
12.
Check the oil level according to the procedure shown in the Diesel Engine Manual.
If necessary, add oil according to the procedure shown in the Diesel Engine Manual.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left doors (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
Change oil according to the procedure shown in the Diesel Engine Manual.
NOTE
In the engine under guard there is hole through which the screw can be removed and the oil pan drained.
10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. Replace the oil filter according to the procedure shown in the Diesel Engine Manual.
10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
WARNING!
The coolant line is pressurized; do not perform any check until the engine has cooled down and, even if the
engine is cold, the tank plug (B) must be opened with extreme care.
7.
8.
Check that the coolant level in the tank (A) is between the minimum and maximum marks, according to the procedure shown
in the Diesel Engine Manual. If necessary, unscrew the plug (B) and top up.
Coolant components:
• 50% of AGIP antifreeze
• 50% of water
After top up, tighten the plug (B).
Perform steps 3 to 6 in the reverse order.
B
A
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ENGINE AIR FILTER CLEANING
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning operations using compressed air
gun.
Preliminary operations
1.
2.
3.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Pre-filter cleaning
4.
5.
Remove the screw (A), then remove the pre-filter (B).
Clean and wash the pre-filter, then install it. Replace it if necessary.
Filter cleaning
6.
7.
8.
9.
Remove the knob (C), then remove the cover (D).
Remove the mounting knob (E) and remove the air filter element (F).
Remove the mounting nut (G) and remove the air filter element (H).
Clean the air filter elements (F) and (H) carefully with compressed air (maximum 87 psi (6 Bar)) and replace them, if
necessary.
10. Reinstall the air filter elements (F) and (H).
11. Install the cover (D) and fasten the knob (C).
12. Close the left door (18) by engaging the fasteners (19) with the supplied key.
A
B
C
F
D
E
G
H
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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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. Replace the fuel filter according to the procedure shown in the Diesel Engine Manual.
10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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SERVICE MANUAL
MOTORE KUBOTA V1505T
FUEL HOSE AND FITTING 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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. Check the fitting seal on the fuel filter (A) and on the injection pump (D). Replace if necessary.
10. Check the seal of the lower fitting (G) and upper fitting (H) on the fuel tank (F). Replace if necessary.
11. Check the integrity of the fuel system hoses on the fuel filter (A) and on the injection pump (D):
• Fuel filter - fuel tank hose (B)
• Fuel filter - injection pump hose (B)
• Injection pump - injectors hose (E)
• Engine body - fuel tank hose (F)
If the clamps are loose, apply oil on the clamp screw and then tighten the clamp.
If the hoses are worn and/or damaged, replace them together with the clamps.
12. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
13. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
H
E
B
F
D
F
G
A
C
S341033
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ENGLISH
MOTORE KUBOTA V1505T
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. To check the tension of the alternator belt (A) remove the protection (B) by unscrewing the mounting screws (C).
10. In the point between the two pulleys (D) press with the thumb with a force of 22 lb (10 kg), the alternator belt (A) must bend (G)
within 0.27 to 0.35 in (7 to 9 mm).
11. If the tension of the belt (A) is not properly adjusted, loosen the two mounting screws (E) of the alternator. By using the tie rod
(F) change the position of the alternator so that the tension of the belt (A) is within acceptable limits.
12. Tighten the two screws (E) and check the tension of the belt (A) again. If ok, perform steps 3, 4, 5, 6, 8 and 9 in the reverse
order.
13. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
F
E
C
B
G
C
E
D
A
S341034
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MOTORE KUBOTA V1505T
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screws (42 and 44) and open the right and left tanks (7 and 16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Remove the protection (E) under the radiator (M) by loosening the screws (F) on both sides.
Remove the alternator belt protection (G) by loosening the screws (H).
The fan protection grid (I and J) by loosening the mounting screws.
On the frame side, remove the lower vibration-dampers (K) of the radiator (M) on both sides.
On the frame side, remove the upper vibration-dampers (L) of the radiator (M) on both sides.
Pull out the engine cooler (M) as necessary to create a minimum space between the fan and the deflector.
If the compressor pulley (D) is installed on the machine, it must be removed.
Loosen the screws (C) and move the alternator (B) toward the inside, to loosen the tension of the alternator belt (A).
Remove the alternator belt (A) through the fan.
Remove the belt (A) and adjust the tension as shown in “Alternator belt tension check” paragraph.
Perform steps 3, 4, 5, 6, 8, 9, 10, 11, 12, 13, 14, 15, 16 and 17 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
J
L
M
C
B
I
C
A
G
D
F
E
F
K
H
H
S341035
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ENGLISH
MOTORE KUBOTA V1505T
RADIATOR FIN CHECK 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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left doors (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
On both sides of the machine, loosen the screws (42 and 44), and open the right and left tanks (7 and 16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
Clean the engine radiator (A) with pressurized water, both inside (D) and outside (B and C).
WARNING!
Especially when cleaning the outer side of the radiator (A) with pressurized water keep a distance of 59 in
(1.5 m) from the radiator, in order not to bend the fins or damage the radiator.
10. Check the radiator fin cleaning according to the procedure shown in the Diesel Engine Manual.
11. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
B
D
C
A
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MOTORE KUBOTA V1505T
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left doors (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screws (44) and (42) and open the right (16) and left tanks (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
10.
11.
12.
13.
Check that the radiator hoses (E) are fastened and integral. Check:
• The lower sleeve (A) both on the engine side and the expansion tank side (F)
• The upper sleeve (B) both on the engine side and the expansion tank side (F)
• The lower sleeve (D) both on the radiator side (E) and the expansion tank side (F)
• The upper sleeve (D) both on the radiator side (E) and the expansion tank side (F)
If the sleeve clamps are loosen, apply oil on threads and fasten securely.
If the sleeves are worn and/or damaged replace them together with the clamps. If it necessary to replace one or more sleeves,
it is advisable to drain the cooling system.
Perform steps 3, 4, 5, 6, 8 and 9 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
F
C
B
E
A
D
S341037
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ENGLISH
MOTORE KUBOTA V1505T
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right and left doors (20) and (18) by releasing the fasteners (21) and (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
Open the expansion tank by removing the plug (B).
WARNING!
Do not remove the expansion tank plug (B) when the engine is hot. Slightly unscrew the plug to the first click to
release the pressure, then remove it.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Place a container (minimum capacity 2.6 USgal (10 liters)) under the filler neck (D) to collect the engine coolant.
Disconnect the radiator lower sleeve (C) and drain the coolant inside the container.
Reconnect the sleeve (C).
Pour new coolant in the expansion tank filler neck (A) up to the “MAX” level.
Tighten the plug (B) firmly.
Start the engine and let it run for a few minutes.
Turn off the engine and let it cool down. Check the level again. If it is still under the “MAX” level, top up again.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
B
A
D
C
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SERVICE MANUAL
MOTORE KUBOTA V1505T
ENGINE SPEED SENSOR 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.
Disconnect the cable (B) from the engine speed sensor (A).
Loosen the mounting nut (C).
Ensure that the flywheel tooth (D) is at the centre of the hole (E). If necessary move the tooth (D) by turning the pulley (F).
Screw down the new sensor (A) until it is flush with the tooth (D).
Then, unscrew the sensor (A) for one turn.
CAUTION!
Apply a thread locking compound to the engine speed sensor (A).
8. Connect the cable (B).
9. Start the machine and check that, when the accelerator is fully pressed, the display shows 2,800 rpm.
10. Fasten the sensor with the nut (C).
F
D
E
C
A
B
S341029
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SERVICE MANUAL
ENGLISH
IMPIANTO DI CLIMATIZZAZIONE
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
I)
Low pressure connection
J) Cooling controls
K) Heating controls
L) Heater
M) Air filter
J
B
E
F
K
L
H
G
I
A
D
M
C
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SERVICE MANUAL
IMPIANTO DI CLIMATIZZAZIONE
TROUBLESHOOTING
No fresh air from the climate control system
Possible causes:
1. The compressor does not turn because the drive belt is loosen/broken (tension/replace the belt).
2. There are gas leaks from the system (repair the leak and integrate the gas).
3. The expansion valve is faulty (replace).
No hot air from the climate control system
Possible causes:
1. The hot water hoses are broken (replace).
2. There are water leaks from the heater (replace).
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IMPIANTO DI CLIMATIZZAZIONE
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
In the point between the two pulleys (C) press with the thumb with a force of 22 lb (10 kg), the alternator belt (A) must bend (B)
within 0.27 to 0.35 in (7 to 9 mm).
10. If the tension of the belt (A) is not properly adjusted, loosen the two mounting screws (D) of the alternator. By using the tie rod
(E) change the position of the alternator (F) so that the tension of the belt (A) is within acceptable limits.
11. Tighten the two screws (D) and check the tension of the belt (A) again. If ok, perform steps 3, 4, 5, 6 and 8 in the reverse
order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
C
A
B
E
D
D
F
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SERVICE MANUAL
IMPIANTO DI CLIMATIZZAZIONE
COMPRESSOR 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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
10.
11.
12.
13.
14.
15.
Loosen the mounting screws (A) of the compressor (B).
Move the alternator (B) toward the inside, to loosen the tension of the belt (C).
Remove the belt (C) from the pulleys.
Place the new belt (C) on the pulleys.
Adjust the compressor belt tension according to the procedure shown in the previous paragraph.
Perform steps 3, 4, 5, 6 and 8 in the reverse order.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
C
A
A
B
S341040
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SERVICE MANUAL
ENGLISH
IMPIANTO DI CLIMATIZZAZIONE
COMPRESSOR 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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (42) and open the left tank (7).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. Use a recharging station to recovery the R134A coolant (A).
10. Before disconnecting the climate control system hoses, check if the system can be repaired without discharging the gas. If it is
not possible, recover the gas as shown in the recharging station Manual.
11. Disconnect the hoses on the fittings (F).
12. Disconnect the connector (G).
13. Remove the mounting screws (D) of the compressor (B).
14. Move the alternator (B) toward the inside, to loosen the tension of the belt (C).
15. Remove the belt (C) from the compressor pulley (E).
16. Install the new compressor by performing steps 11, 12, 13, 14 and 15 in the reverse order.
17. Adjust the compressor belt tension according to the procedure shown in the previous paragraph.
18. Create vacuum in the system as shown in the recharging station Manual.
19. Charge the system as shown in the recharging station Manual.
20. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
21. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
C
F
A
F
G
D
E
D
B
S341042
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SERVICE MANUAL
IMPIANTO DI CLIMATIZZAZIONE
AIR FILTER REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws (A) and the panel (B) in the cab.
Unscrew the knobs (F) and remove the panel (C).
Remove the cab air filter (D).
Install the new filter (D) with the arrows (E) pointing in the direction of the air flow (upwards).
Perform steps 3 and 4 in the reverse order.
A
F
A
B
A
C
F
A
D
E
S341041
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SERVICE MANUAL
ENGLISH
IMPIANTI VARI
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 doors (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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screws (42 and 44) and open the right and left tanks (7 and 16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
Inspect the machine accessible parts and check for:
• Tightening of mounting screws and nuts;
• Correct position of the fasteners;
• Visible faults in the components;
• Leaks of fluids (oil, etc.).
10. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
11. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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SERVICE MANUAL
IMPIANTI VARI
LUBRICATION
1.
2.
3.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Lubricate the rear axle knuckles with the grease nipples (A). If necessary, steer the rear wheels to reach the grease nipples
easily.
Grease quantity to be applied:
• 2 - 3 pumping, in case of a manual pump.
• 8 - 12 seconds of injection, in case of an air pump.
A
A
A
A
S341043
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SERVICE MANUAL
ENGLISH
IMPIANTO IDRAULICO
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 (21 cc), activated by the diesel engine. This pump activates two drive system
motors, which operate on the front wheels. The circuit is monitored by a pressure inlet (115).
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 (14 cc), activated by the diesel engine. This pump activates the suction fan motor by
means of the distributor. The circuit is monitored by a pressure inlet (116).
The third circuit is supplied by a gear pump (9.6 cc) with priority valve, activated by the diesel engine. The circuit is monitored by a
pressure inlet (117).
This pumps, by means of the distributor, performs the following functions:
–
Side broom motor activation
–
Hopper lifting and dumping
–
Suction inlet lifting
–
Rear wheel control hydraulic cylinder activation (by means of the oil taken from the priority valve).
All circuits are protected by suction filters and safety valves.
NOTE
The hydraulic fittings is DIN type.
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SERVICE MANUAL
IMPIANTO IDRAULICO
COMPONENT LOCATION
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
Hydraulic system oil tank
Drain filter
Suction filter
Oil cooler bulb
Drive system pump
Hydraulic system oil level float
Left drive system motor
Suction inlet/hopper distributor
Right drive system motor
Skirt cylinder
Hopper lifting cylinder
Hand pump
Right broom motor
Left broom motor
Hydraulic system oil cooler
Parachute valve
Suction inlet and broom lifting cylinder
Check valve
Power steering
Flow separator (priority valve)
Accessory and steering system pump
Suction fan pump
Fan/optional distributor
Skirt solenoid valve
Suction fan motor
Power steering cylinder
Drive pedal assist
Hydraulic system oil level indicator
Drive system pump oil filter
High-pressure washing system pump (*)
Broom speed adjuster (*)
Hydraulic system oil filler plug
(*) On some versions only
(**) Optional
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ENGLISH
IMPIANTO IDRAULICO
COMPONENT LOCATION (Continues)
81
61
51
77
55
52
52
52
57-69
72
50
53 64
62
74
76
60
66
80
68
67
58
73
79
59
63
66
70
56
71
75
78
54
65
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SERVICE MANUAL
IMPIANTO IDRAULICO
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.
82.
Hydraulic system oil tank
Suction filter
Suction filter
Suction filter
Drive system pump
Diesel engine
Left drive system motor
Right drive system motor
Distributor
Skirt cylinder
Hopper lifting cylinder
Hand pump
Right broom motor
Left broom motor
Hydraulic system oil cooler
Parachute valve
Suction inlet and broom lifting cylinder
Check valve
Power steering
Flow separator (priority valve)
Accessory and steering system pump
Suction fan pump
Distributor
Solenoid valve
Suction fan motor
Power steering cylinder
Drive pedal assist
Oil drain filter
Drive system pump oil filter
High-pressure washing system pump (*)
Flow regulator (**)
Breather/filler plug
High pressure pump safety solenoid valve (*)
(*) On some versions only
(**) Optional
100
33019746(2)2010-03
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79
81
P
B
A
T
64
P
B
USCITÀ ACQUA/
WATER OUTLET
71
B
B
L1
57
18bar
A
DX
M1
M2
RS 501
50
10µm
77
250bar
250bar
51
52
L2
T
1:1
53
60µm
10µm
81
S
9cc
P
P1
60µm
54
b
21cc
B
60µm
a
A
70
1:1
1
69
2
3
68
13.1 l/min
62
80cc
130bar
T
90bar
P
67
1
2
A1
B1
8.7 l/min
CAPACITÀ SERBATOIO/TANK CAPACITY: 40.6 lt.(10.73 U.S. gal.)
CAPACITÀ IMPIANTO/SYSTEM CAPACITY: 58 lt.(15.32 U.S. gal.)
2600 RPM
(MAX)
21.8 l/min
55
M
10µm
78
P
B
C2
66
80
58
80cc
40cc
63
3
T
A2
B2
61
150bar
150bar
2
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WATER INLET
72
210bar
T
SX
A
20
A
73
P
R
L
EV3
B
11.23cc
74
(Standard)
76
C1
40X95X
0
A
20
1
A
66
40X95X
1
3
N 2
30bar
B
4
2
40X70X
A
60
35
EV2
59
48X85
75
25
65
50X350X
32
T
SERVICE MANUAL
ENGLISH
IMPIANTO IDRAULICO
HYDRAULIC DIAGRAM (Continues)
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TROUBLESHOOTING
See the previous chapters related to the use of the 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.
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 Instructions for use Manual.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Check that the needle of the efficiency indicator (D) of the drain filter (C) is in the green area (E), otherwise the filter (C) must
be replaced (see the procedure in the relevant paragraph).
Check that there are no oil leaks in the upper area (F) of the hydraulic system oil tank.
Turn the ignition key (76) to OFF position and remove it.
Using the indicator (A), check that the oil level in the tank is between the MIN and MAX marks.
CAUTION!
If the hydraulic oil level is low, the warning light (84) turns on and the machine stops after 20 seconds.
8.
If necessary, unscrew the plug (G) and top up. For the types of oil to be used, see the Technical Data chapter.
NOTE
Top up by using the same type of oil that is in the tank.
9. Screw down the plug (G).
10. Close the right door (20) by engaging the fasteners (21) with the supplied key.
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HYDRAULIC SYSTEM OIL LEVEL SENSOR REPLACEMENT
CAUTION!
When there is a short in the level sensor, the detection system determines that the oil level is low and stops the
machine after about 20 seconds. When there is an open in the lever sensor, the detection system determines
that the oil level is high.
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).
Open the right door (20) by releasing the fasteners (21) with the supplied key.
With a suitable ladder, reach the upper side of the hydraulic oil tank (33).
Locate the level sensor (A).
Disconnect the connector (B).
With a Ø27 socket wrench, unscrew the sensor (A) and replace it.
Connect the connector (B) to the sensor.
Close the right door (20) by engaging the fasteners (21) with the supplied key.
B
A
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HYDRAULIC SYSTEM OIL AND SUCTION FILTER REPLACEMENT
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 door (20) by releasing the fasteners (21) with the supplied key.
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
6.
Remove the oil drain hose (A) from under the tank (33), place a container (minimum capacity 15.8 USgal (60 liters)) under the
hose (A), then unscrew the plug (B) and drain the oil into the container.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil should be disposed of properly according to the environmental Laws in force.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
With a suitable ladder, reach the upper side of the hydraulic oil tank (33).
Unscrew and remove the filler plug (C).
Remove the cover (D) by unscrewing the mounting screws (E).
Unscrew and replace the suction filter (G).
Replace the drain filter element (H) (see the procedure in the relevant paragraph).
Reinstall the cover (D) and fasten it with the screws (E). Also check the gasket (F) for integrity, and replace it if necessary.
Screw down the plug (C) and reinstall the oil drain hose (A) under the tank.
Pour oil in the tank (I) through the plug filler neck (C). For oil types and quantity, see the Technical Data chapter.
Fill the tank until the oil level reaches the MAX mark of the indicator (J).
Screw down the filler plug (C).
Start the diesel engine as shown in the relevant Manual. Run the system for a few minutes.
Check the hydraulic oil level by means of the indicator (J). If the level is under the MAX mark, top up through the filler plug (C).
Close the right door (20) by engaging the fasteners (21) with the supplied key.
If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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HYDRAULIC SYSTEM OIL CHANGE (Continues)
A
C
H
J
D
F
E
G
I
B
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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 door (20) by releasing the fasteners (21) with the supplied key.
Unscrew and remove the cover (A).
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in
force.
5.
6.
7.
Remove the drain filter (B) and replace it with a new one.
Install the cover (A).
Close the right door (20) by engaging the fasteners (21) with the supplied key.
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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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9.
Remove the screw (A) and the filter (B) behind the right front wheel.
If necessary, to reach the filter, remove the right front wheel according to the procedure shown in the relevant paragraph.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
CAUTION!
The hydraulic system oil and filters should be disposed of properly according to the environmental Laws in
force.
10. Install a new filter (B) and fasten it with the screw (A).
11. Perform steps 3, 4, 5, 6 and 8 in the reverse order.
12. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
B
A
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HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK
WARNING!
Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using compressed
air or water gun.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Clean the hydraulic system oil cooler fins (A) with compressed air (max. 87 psi (6 Bar)). If necessary, point the compressed air
in the opposite direction of the cooling air.
Inside the radiator (A), check that the fan (B) turns freely.
Perform steps 3 to 6 in the reverse order.
B
A
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STEERING CYLINDER DISASSEMBLY/ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
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 nuts (C) fastening the cylinder assembly (D) to the rear axle forks.
Remove the screws (E), then remove the steering cylinder assembly (D).
Remove the articulations (F) and install them on the new steering cylinder.
Install the steering cylinder assembly performing steps 3 to 5 in the reverse order.
Adjust the rear axle toe-in (see the procedure in the relevant paragraph).
Check the hydraulic system oil level (see the procedure in the relevant paragraph).
A
A
E
E
C
B
C
A
F
F
D
B
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HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
Disassembly/assembly of the following hydraulic cylinders:
–
–
–
Suction inlet right cylinder (A)
Suction inlet left cylinder (A)
Skirt cylinder (C)
CAUTION!
This procedure must be performed with the hopper (3) fully retracted.
1.
2.
3.
4.
Engage the parking brake with the lever (66).
Bring the suction inlet in the most suitable position.
Turn the ignition key (76) to OFF position and remove it.
Disconnect the hoses from the hydraulic cylinder and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
5.
6.
7.
Disconnect and remove the hydraulic cylinder and, if necessary, support appropriately the components connected to the
cylinder.
Perform steps 2 to 5 in the reverse order.
Start the machine and check that the hydraulic cylinder operates properly, then stop the machine, check the hydraulic system
oil level and, if necessary, top up (as shown in the Instructions for use Manual).
Disassembly/assembly of the following hydraulic cylinder:
–
Hopper lifting cylinder (D)
8.
9.
10.
11.
12.
13.
14.
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 Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the right door (20) by releasing the fasteners (21) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Disconnect the hoses from the hydraulic cylinder and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
15. Disconnect and remove the hydraulic cylinder and, if necessary, support appropriately the components connected to the
cylinder.
16. Perform steps 3 to 8 in the reverse order.
17. 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 Instructions for use Manual).
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HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY (Continues)
A
B
C
A
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IMPIANTO IDRAULICO
SUCTION FAN DISTRIBUTOR 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 distributor (A) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
3.
4.
5.
6.
7.
8.
Loosen the locknut (C) and remove the lever (B).
Remove the screws (D), then remove the distributor (A).
If necessary, remove the fittings and the distributor at the workbench.
Assemble the components in the reverse order of disassembly.
Check the hydraulic system oil level (see the procedure in the relevant paragraph).
Check the hydraulic system oil pressure at the suction fan pump (see the procedure in the relevant paragraph).
B
C
D
A
D
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ACCESSORY SYSTEM DISTRIBUTOR REMOVAL/INSTALLATION
CAUTION!
This procedure must be performed with the hopper (3) fully lowered.
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.
4.
If necessary, bleed the hydraulic system oil from the tank (see the procedure in the relevant paragraph).
Remove the screws and the right panel (22) on the right side of the cab.
Mark the position of the hoses connected to the accessory system distributor (A) (for proper reassembly).
Disconnect all the hoses from the distributor (A) and plug them immediately.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
5.
6.
7.
8.
9.
10.
Loosen the locknut (C) and remove the levers (B).
Remove the screws (D), then remove the distributor (A).
If necessary, remove the fittings and the distributor at the workbench.
Assemble the components in the reverse order of disassembly.
Pour oil in the tank (see the procedure in the relevant paragraph) until the level reaches the MIN mark of the indicator.
Start the machine, use the drive system and lift/lower the hopper a few times. Check that controls (60), (62) and (63) operate
properly. Then stop the machine, check the hydraulic system oil level and, if necessary, top up (as shown in the Instructions for
use Manual).
11. Check the hydraulic system oil pressure at the accessory and steering system pump (see the procedure in the relevant
paragraph).
D
C
C
A
B
B
D
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ACCESSORY AND SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY
CAUTION!
This procedure must be performed with the hopper (3) fully retracted (as shown in the figure).
CAUTION!
If necessary, remove the bonded sealing washers and replace them.
1.
2.
3.
4.
5.
6.
7.
8.
Empty the hopper (3); if it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Lift the hopper (3), according to the procedure shown in the Instructions for use Manual.
Turn the ignition key (76) to OFF position and remove it.
Open the left door (18) by releasing the fasteners (19) with the supplied key.
Remove the locking pins (28) from the housings (29) and place them into the holes (30).
Empty the dust control system water tanks (7 and 16) according to the procedure shown in the relevant paragraph.
Remove the screw (44) and open the right tank (16).
WARNING!
Open the tanks (7 and 16) only if they are empty: Each tank contains 264.5 lb (120 kg) of water approximately.
9. Remove the suction inlet (see the procedure in the relevant paragraph).
10. Mark the position of the hoses connected to the fittings (A) of the tandem pump (B) (for proper reassembly).
11. Disconnect the hoses from the fittings (A) of the tandem pump (B) and plug them immediately. Collect the hydraulic system oil
that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
12.
13.
14.
15.
16.
Remove the screws (C), then remove the tandem pump (B).
Recover the protection (D) of the pump (B).
Recover the fittings (E) of the tandem pump at the workbench.
Assemble the components in the reverse order of disassembly.
Start the machine, lift/lower the hopper and activate the brooms a few times, then stop the machine, check the hydraulic
system oil level and, if necessary, top up (as shown in the Instructions for use Manual).
17. Check the oil pressure at the pressure inlets (see the procedure in the relevant paragraph).
18. If necessary, fill the dust control system water tanks according to the procedure shown in the Instructions for use Manual.
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ACCESSORY AND SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY (Continues)
A
E
A
D
E
B
A
E
A
C
E
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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 tandem pump (D) (for
proper reassembly).
Disconnect the hoses from the fittings (A) of the drive system pump (B) and of the tandem pump (D), and plug them
immediately. Collect the hydraulic system oil that comes out of the hoses before plugging them.
WARNING!
Hydraulic system oil is highly corrosive, wear rubber gloves.
4.
5.
6.
7.
8.
9.
Remove the screws (C), then remove the coupled pumps (B) and (D).
Recover the drive system pump fittings (A) at the workbench.
Remove the screws (E), then separate the tandem pump (D) from the drive system pump (B).
Assemble the components in the reverse order of disassembly.
Start the machine, use the drive system and activate the accessories, then stop the machine, check the hydraulic system oil
level and, if necessary, top up (as shown in the Instructions for use Manual).
Check the hydraulic system oil pressure at the pressure inlets (see the procedure in the relevant paragraph).
A A
A
A
A
C
A
A
A
A
C
B
E
A
D
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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.
2.
3.
4.
5.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the right panel (22) on the right side of the cab.
Connect a pressure gauge (A), with a minimum scale of 3,626 psi (250 Bar) equipped with capillary tube (B), to the pressure
inlet (C).
Measure the suction fan pump pressure according to the following procedure.
Pressure measurement
6.
Start the machine and run the engine at maximum speed (as shown in the Instructions for use Manual). In this condition,
turn the lever (D) to “OPT” position and check that the pressure measured by the pressure gauge (A) is 3,191 psi (220 Bar)
approximately.
• If the pressure is normal, disengage the lever (D) and turn off the machine.
• If the pressure is higher or lower, it can be adjusted according to the following procedure, while keeping the machine
accelerated and the lever (D) engaged.
Pressure adjustment
7.
8.
Unscrew the cap (G).
Loosen the locknut (E) and slightly turn the internal threaded dowel (F) to adjust the pressure. If the pressure cannot be
adjusted to normal values, probably the pump needs to be replaced (see the procedure in the relevant paragraph).
9. Disengage the lever (D) and turn off the machine.
10. Tighten the locknut (E) and screw down the cap (G).
Reset
11. Perform steps 3 and 4 in the reverse order.
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HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP (Continues)
A
200
100
2000
psi
bar
3000
4000
300
DIN16007
1000
0
5000
5800
B
D
C
G
E
F
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HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY SYSTEM PUMP
NOTE
This check is necessary in case of malfunction of the accessory system and steering system.
Preliminary operations
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).
Turn the ignition key (76) to OFF position and remove it.
Remove the screws and the right panel (22) on the right side of the cab.
Connect a pressure gauge (A) with a minimum scale of 2,176 psi (150 Bar) equipped with the capillary tube (B).
Measure the accessory pump pressure according to the following procedure.
Pressure measurement
7.
Start the machine and run the engine at maximum speed (as shown in the Instructions for use Manual). In this condition,
engage the lever (D) to lift the hopper and check that the pressure measured by the pressure gauge (A) is 1,740 psi (120 Bar)
approximately.
• If the pressure is normal, disengage the lever (D) and turn off the machine.
• If the pressure is higher or lower, it can be adjusted according to the following procedure, while keeping the machine
accelerated and the lever (D) engaged.
Pressure adjustment
8.
9.
Unscrew the cap (G).
Loosen the locknut (E) and slightly turn the internal threaded dowel (F) to adjust the pressure. If the pressure cannot be
adjusted to normal values, probably the pump needs to be replaced (see the procedure in the relevant paragraph).
10. Disengage the lever (D) and turn off the machine.
11. Tighten the locknut (E) and screw down the cap (G).
Reset
12. Perform steps 4 and 5 in the reverse order.
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HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY SYSTEM PUMP (Continues)
A
200
100
2000
psi
bar
3000
4000
300
DIN16007
1000
0
5000
5800
B
D
C
G
E
F
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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.
2.
3.
4.
Empty the hopper (3). If it contains a small quantity of waste, it is not necessary to dump it.
Drive the machine on a solid and level ground and engage the parking brake with the lever (66). To perform the inspection,
indicated in the next step 9, in a safe condition, the ground opposite the machine have to be free from obstruction and leveled.
Turn the ignition key (76) to OFF position and remove it.
Remove the screw (42), open the left water tank (7) and disconnect the fastener, then fully open the tank.
WARNING!
Open the left tank (7) only when it is empty: the tank contains 264 lb (120 kg) of water approximately.
5.
6.
Connect a pressure gauge (E), with a minimum scale of 4,351 psi (300 Bar) equipped with the extension, to the pressure inlet
(B) of the drive system pump.
Measure the drive system pump pressure according to the following procedure.
Pressure measurement
7.
8.
Start the machine and run the engine at maximum speed (as shown in the Instructions for use Manual).
Fully engage the parking brake with the lever (66).
WARNING!
To perform the inspection, indicated in the next step 9, in a safe condition, keep the personnel away from the
front of the machine and remove any obstructions.
9.
Press and hold the brake pedal (57), then fully press the drive pedal (56) (if the machine moves, release the drive pedal (56),
then try again by firmly pressing the brake pedal (57)). Check that the pressure on the pressure gauge (A) is within 2,901 and
3,626 psi (200 and 250 Bar).
• If the pressure is normal, release the drive pedal (56) and turn off the machine.
• If the pressure is lower than specified, check if the fault is related to the drive system pump or to the drive pedal assist.
Reset
10. Perform steps 4 and 5 in the reverse order.
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HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP (Continues)
C
B
A
0
200
5000
3000
4000
DIN16007
5800
2000
psi
bar
1000
100
300
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IMPIANTO ELETTRICO
ELECTRICAL SYSTEM
DESCRIPTION
The electrical system is power-supplied from the alternator, which is activated by the diesel engine.
The battery is 12 V.
The accessory electrical circuit are protected by lamellar fuses located in the fuse boxes inside the dashboard.
The power electrical circuits are protected by Maxi fuses located inside the cab left panel (23).
A manual battery release device (100 A), connected on battery negative terminal and frame, does not allow for machine start-up if it
is not activated.
An emergency push-button on the left side of the dashboard disables all the accessories except the hazard warning lights.
COMPONENT LOCATION
A1
Control electronic board
H13
Right front high beam
A2
Display electronic board
H14
Left brake light
F1.0
Power fuse terminal board
H15
Left front turn signal
F1.1
Glow plug fuse (40 A)
H16
Right front turn signal
F1.2
Line fuse (60 A)
H17
Left rear turn signal
F1.3
Start-up fuse (40 A)
H18
Right rear turn signal
F1.4
Alternator fuse (60 A)
H19
Horn
F2.0
Fuse box inside the cab
H2
Fuel level warning buzzer
F2.1
Turn signal fuse (30) (10 A)
H20
Reverse gear buzzer
F2.2
Brake light/brake light microswitch/reverse gear buzzer/horn
fuse (10 A)
H21
Cigarette lighter socket light
H22
Ceiling light bulb
H23
Lifted hopper warning light
H24
High beam indicator light
H25
Running light indicator light
H26
Turn signal indicator light
H27
Charged battery indicator light
H28
Engine oil low pressure warning light
H29
Check engine warning light
H3
Rotating beacon
H30
Hydraulic system oil low level and hydraulic system fault
warning light
H31
Glow plug pre-heating warning light
H32
Engaged parking brake warning light
H33
Right brake light
H4
Suction inlet working light
H5
License plate light
H6
Left rear running light
H7
Right rear running light
H8
Left front running light
H9
Right front running light
K1
Glow plug activation relay
K10
Engaged parking brake warning light relay
K11
Running light relay
K12
Climate control system compressor relay
K13
Climate control system fan relay
K14
Engine shutdown relay
F2.3
Running light fuse (10 A)
F2.4
Running light fuse (10 A)
F2.5
Low beam fuse (15 A)
F2.6
High beam fuse (15 A)
F2.7
Key lock, main relay, combination switch/audio unit fuse (+30)
(10 A)
F2.8
Accessory socket power supply fuse (15 A)
F3.1
Oil cooler electric fan and solenoid valve control fuse (20 A)
F3.2
Fuel solenoid valve, engine stop, +15 alternator fuse (15 A)
F3.3
Rotating beacon/climate control system switch/climate control
system fan fuse (20 A)
F3.4
Water motor pump/windscreen wiper/washer system pump/
climate control system compressor and high pressure pump
safety solenoid valve fuse (20 A)
F3.5
Dashboard power supply/safety electronic board/sensors/
ceiling light/audio unit fuse (+15) (15 A)
F3.6
Turn signal fuse (+15) (15 A)
F3.7
Climate control system compressor fuse (15 A)
F3.8
Hydraulic jack/switch back-light fuse (15 A)
G1
Battery
G2
Alternator
H1
Disengaged parking brake buzzer
H10
Left front low beam
H11
Right front low beam
H12
Left front high beam
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COMPONENT LOCATION (Continues)
K2
Main relay
S13
Service brake microswitch
K3
Gear enabling valve power supply/jack enabling relay
S14
Hazard warning light switch
K4
Engine start relay
S15
Lifted hopper limit switch
K5
Brake light relay
S16
Engine oil low pressure switch
K6
Water delivery relay
S17
Driver’s seat microswitch
K7
Low beam/working light relay
S18
Water temperature sensor
K8
High beam relay
S19
Fuel level sensor
K9
Actuator unlock relay
S2
Reverse gear sensor
L1
Fuel solenoid valve holding solenoid valve
S20
Engine speed sensor
L2
Fuel solenoid valve energizing solenoid valve
S21
Windscreen wiper/washer switch
L3
High pressure pump safety solenoid valve
S22
Hydraulic system oil level sensor
L4
Skirt opening solenoid valve
S23
Hydraulic system oil cooling thermostat
L5
Skirt closing solenoid valve
S24
Skirt opening selector
M1
Starter
S25
Skirt closing selector
M2
Dust control system water motor pump
S26
Climate control system fan 2-speed switch
M3
Door opening/closing actuator
S27
Climate control system switch
M4
Windscreen wiper motor
S28
Climate control system maximum pressure switch
M5
Windscreen washer system pump motor
S29
Climate control system control knob
M6
Hydraulic system oil cooling fan motor
S3
Emergency push-button
M7
Climate control system exchanger motor
S30
Ceiling light switch
M8
Climate control system compressor clutch
S4
Engaged parking brake microswitch
M9
Cab blower
S5
Water tank level sensor
R1
Pre-heating glow plugs
S6
Dust control system switch
R3
Cab blower rheostat
S7
Door opening/closing switch
S1
Forward gear sensor
S8
Light switch
S10
Suction inlet light switch
S9
Display selector
S11
Battery release switch
X15
Cigarette lighter socket
S12
Ignition switch
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COMPONENT LOCATION (Continues)
H3
M4
H16
H9-H11-H13
H19
H4
H15
M2
H8-H10-H12
S15
H20
M3
H6-H14-H18
M7
H5
M8
H7-H17-H33
G2
S20 M1
M6
L1-L2-R1
S16-S18
S341070
(*)
See the Diesel Engine Manual
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COMPONENT LOCATION (Continues)
S19
S28
S23
S22
S5
S17
S8
H21-X15
S11
S4
F1.1-F1.2
F1.3-F1.4
M5
S24-S25
G1
L3
M9
S29
R3 S13
K1-K2-K4
S1
L4-L5
S2
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COMPONENT LOCATION (Continues)
S30
H22
S27
S6
S9
S14
S7
S3
F2.2
F2.4
F2.3
F2.1
F2.5
S12
F2
F3
F3.6
F3.8
H26 H27 H28 H29 H30
F3.2
H31
F3.4
H32
H25
346798.05
H24
ENG
rpm
F3.7
F3.3
F3.1
F3.5
H23
%
100
105
A2
K7
K11
K14
K10
K5
K12
K12
K14
K10
K5
.
Unival
.
K9
.
.
Unival
.
K9
.
Unival
.
.
Unival
.
K3
.
Unival
.
.
Unival
.
K14
K10
K3
.
Unival
.
.
Unival
.
K7
K7
.
Unival
.
.
Unival
.
K8
.
Unival
.
.
Unival
K8
.
Unival
.
.
.
K6
.
Unival
.
Unival
K11
.
Unival
K12
K9
K8
K6
F2.7
K6
F2.8
H1-H2
S26
A2
S10
K13
F2.6
S21
.
K6
K3
A1
K5
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TROUBLESHOOTING
See the previous chapters related to the use of the electrical system.
Other possible causes:
1. The battery is not efficient (perform maintenance/replace).
2. The fuses are open (replace).
3. The relays are faulty (replace).
4. The control panel display is faulty (replace).
5. The harness is cut or pressed (repair).
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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.
8.
9.
Engage the parking brake with the lever (66).
Turn off the engine, by turning the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Remove the 2 screws and open the cab left door (23).
Check the color of the hygrometer (90); if it is green the battery is ok, if is red:
• The battery must be refilled with distilled water
• The battery must be charged.
If the hygrometer color is still red, the battery must be replaced.
If necessary, clean the battery.
Check the battery terminal connections for oxidation.
Close the cab left door (23) and tighten the screws.
Insert the battery by installing and turning the key of the release device (91) to horizontal position.
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POWER FUSE REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Engage the parking brake (66).
Turn the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Remove the 2 screws and open the cab left door (23).
Remove the cover (A) of the fuse box (92) and replace the relevant fuse among the following:
A) Glow plug fuse (40 A)
B) Line fuse (60 A)
C) Start-up fuse (40 A)
D) Alternator fuse (60 A)
Install the fuse box cover (A) and close the cab left door (23).
Insert the battery (34) by installing and turning the key of the release device (91) to horizontal position.
A
a
d
b
c
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ACCESSORY FUSE REPLACEMENT
1.
2.
3.
4.
Engage the parking brake (66).
Turn the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Operating on the cab dashboard, remove the transparent cover of the fuse box (F2) or (F3) and replace the suspected fuse
among the following:
Fuse box F2
a)
b)
c)
d)
e)
f)
g)
h)
F2.1: Turn signal fuse (10 A)
F2.2: Brake light, brake pedal microswitch, reverse gear buzzer and horn fuse (10 A)
F2.3: Running light fuse (10 A)
F2.4: Running light fuse (10 A)
F2.5: Low beam fuse (15 A)
F2.6: High beam fuse (15 A)
F2.7: Ignition key lock, main relay, combination switch and +30 audio unit fuse (10 A)
F2.8: Accessory socket power supply fuse (15 A)
Fuse box F3
i)
j)
k)
l)
m)
n)
o)
p)
F3.1: Oil cooler electric fan and solenoid valve control fuse (20 A)
F3.2: Fuel solenoid valve, engine off relay and +15 alternator fuse (15 A)
F3.3: Flashing light, climate control system switch and cab fan switch fuse (20 A)
F3.4: Water pump, windscreen wiper, windscreen washer system pump, climate control system compressor and high pressure
pump safety solenoid valve fuse (20 A)
F3.5: Warning light panel power supply, safety electronic board, drive sensor, ceiling light and +15 audio unit fuse (15 A)
F3.6: +15 turn signal fuse (15 A)
F3.7: Climate control system compressor fuse (15 A)
F3.8: Door actuator and switch back-light fuse (15 A)
5.
Insert the battery (34) by installing and turning the key of the release device (91) to horizontal position.
d
f
h
g
e
b
c
a
F2
F3
o
p
n
m k i
l
j
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POWER RELAY REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Engage the parking brake (66).
Turn the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Remove the 2 screws and open the cab left door (23).
Replace the relevant relay among the following:
A) Main relay
B) Engine start relay
C) Glow plug relay
Install the fuse box cover (A) and close the cab left door (23).
Insert the battery (34) by installing and turning the key of the release device (91) to horizontal position.
A
B
C
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ACCESSORY RELAY REPLACEMENT
1.
2.
3.
4.
5.
Engage the parking brake (66).
Turn the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Remove the screws (A) and lower the dashboard panel (B) in the cab.
Remove the suspected relay among the following:
a) K7:
Low beam/working light relay
b) K8:
High beam relay
c) K11:
Running light relay
d) K6:
Water delivery relay
e) K12:
Climate control system compressor relay
f) K9:
Actuator unlock relay
g) K3:
Gear enabling power supply/door actuator unlock relay
h) K14:
Engine shutdown relay
i) K10:
Engaged parking brake warning light relay
j) K5:
Brake light relay
k) A1:
Function electronic board
l) K13:
Climate control system fan relay
NOTE
The component view (C) is from above and inside the dashboard panel (B).
Assemble the components in the reverse order of disassembly.
B
A
A
C
a
Unival
Unival
Unival
.
.
c
.
K8
K14
K12
K12
K14
K10
Unival
.
K10
Unival
.
K5
Unival
.
K5
Unival
.
K9
.
Unival
.
K9
.
Unival
.
.
K3
.
Unival
.
.
K3
.
Unival
.
.
K7
K7
.
Unival
.
.
h
i
K8
.
Unival
.
.
K6
.
Unival
.
.
K11
.
Unival
.
.
K6
.
Unival
e
f
b
K6
6.
.
d
g
k
j
l
K11
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CONTROL PANEL DISPLAY REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
Engage the parking brake (66).
Turn the ignition key (76) counterclockwise, to the end of stroke, then remove it.
To disconnect the battery (34), turn the key of the release device (91) and then remove it.
Remove the screws (A) and lower the dashboard panel (B) in the cab.
Disconnect the connectors (C).
Remove the nuts (D).
Remove the display (E) and replace it with a new display.
NOTE
The spare parts display can be installed as it is, no calibration is required.
8.
Assemble the components in the reverse order of disassembly.
B
A
A
D
D
D
E
D
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LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT
Preliminary operations
1.
2.
Drive the machine on a solid and level ground, then engage the parking brake with the lever (66).
Turn the ignition key (76) to OFF position and remove it.
Bulb replacement
3.
4.
5.
6.
Remove the screws (A) and the headlight (B) paying attention to the electrical connections.
Replace the burned bulbs.
Install the headlight (B) and fasten it with the screws (A).
Adjust the headlights according to the following procedure.
Low beam adjustment
7.
Use the screws (C) and (D), in the following way:
• To adjust the beam vertically, turn the screws (C) and (D) simultaneously;
• To adjust the beam horizontally, turn the screws (C) and (D) individually.
C
D
A
A
B
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CONTROL PANEL DISPLAY FUNCTIONS
1.
When the key is turned to ON
When the ignition key (76) is turned to the first position, the display (82) shows for a few seconds the first screen (A) with
numbers or symbols that indicate the machine condition. The parameters that can be checked are shown below.
• Scheduled maintenance intervals. MA0 (D) indicates the scheduled maintenance at 200 hours, while MA1 (F)
indicates the scheduled maintenance at 800 hours. If one of the intervals is nearly expired or expired (negative number),
maintenance procedures must be performed as shown in the relevant chapter.
NOTE
When one of the maintenance intervals has expired, one of the symbols (D or F, Fig. H) flashes for a few seconds at
machine start-up.
Display functions:
•
Active transport hour calculation (B).
WARNING!
If the symbol
is not shown, but the key
appears on the display, it means that the maintenance
interval has expired. Proceed as shown in the relevant chapter.
•
•
•
•
•
2.
Number of transport hours (C).
Alarm counter (H). It counts the number of alarms occurred after the last reset of the control unit. If the number is different
from zero, contact a Advance Service Center to reset the system.
Software overhaul (I).
Road sweeper identification number (G). The number “006” identifies the RS 501 model, with Kubota V1505T engine.
Fasten the seat belts. The flashing symbols (E) warns that the seat belts must be fastened.
Transport mode visualization
When the key is turned to ON, the display (82,) automatically shows the transport/working mode visualization (J) thus replacing
the screen (A). The screen (J) remains even after the engine has been turned on. It shows the following parameters.
ENG
• Engine speed: 4-digit number (P) with the following symbol rpm (N).
CAUTION!
If the engine speed sensor is faulty, the switches on the display are not illuminated. Repair the circuit
and replace the engine speed sensor, see the relevant procedure.
•
Fuel level: the fuel level is shown by the horizontal bar indicator (O). The last bars indicate the reserve, they flash when
the level is low. The fuel level instantaneous value in % (Q) is shown too.
CAUTION!
If the fuel level is low, a continuous warning buzzer signals the problem. The warning buzzer can be
reset by pressing the button (41) on “SEL”.
CAUTION!
If the level sensor is faulty, the display shows warning messages according to the type of fault (short or
open circuit) (for the alarm coding see the “Alarm description” paragraph). Repair the circuit and replace
the level sensor, see the relevant procedure.
CAUTION!
If the level sensor is faulty, a continuous warning buzzer signals the problem. The warning buzzer can
be reset by pressing the button (41) on “SEL” for several seconds.
The symbol (R) indicates that the fuel level indicator is activated.
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CONTROL PANEL DISPLAY FUNCTIONS (Continues)
•
Engine coolant temperature: the temperature is shown by the horizontal bar indicator (K). The bars flashes in case
of overheating. The temperature instantaneous value (V) is shown too. The symbol (U) indicates that the temperature
indicator is activated.
CAUTION!
If the coolant temperature is high, the engine stops and a continuous warning buzzer signals the
problem. The warning buzzer can be reset by pressing the button (41) on “SEL” for several seconds.
CAUTION!
If the temperature sensor is faulty, the display shows warning messages according to the type of fault
(short or open circuit) (for the alarm coding see the “Alarm description” paragraph). Repair the circuit
and replace the temperature sensor, see the relevant procedure.
•
•
Dust control system tank water level with the relevant indicator (S):
–
main tank and sub-tank are full
–
main tank and sub-tank are empty. In this condition, the dust control system turns off after about 10 seconds.
Machine operation mode with the relevant indicator (T):
– N, machine movement mode is not regular.
When pressing the drive pedal, the “N” symbol is replaced by the symbol
.
WARNING!
is not shown, but the letter “N” still appears on the
When the drive pedal is pressed, if the symbol
display, it means that the parking brake is engaged (release the lever) or that the pedal sensors are
faulty.
•
Engine operation hours (M) with the relevant symbol (L).
WARNING!
If the symbol
is not shown, but the key
appears on the display, it means that the maintenance
interval has expired. Proceed as shown in the relevant chapter.
B
C
A
D
K
L
O
N
M
J
E
ENG
rpm
%
F
I
H
G
V
U
T
S
R
P
Q
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CONTROL PANEL DISPLAY FUNCTIONS (Continues)
3.
Alarm visualization
When the engine is running, in case of machine malfunctions, the alarms will be shown on the display (82).
These alarms are shown in the visualization (A).
WARNING!
– The alarms are shown for up to 5 seconds. Then the alarm is stored in the B_BOX (see the relevant
paragraph).
– The alarms are shown also in the ALARM LIST (refer to ALARM.01 and ALARM.02 in the relevant
paragraph).
The alarms are indicated by the name “ALARM” (B) and by some symbols which identify the source (C) and the seriousness (D)
of the alarm. The visualization shown on the second line of the text identifies the alarm description (E). For some serious alarms,
the machine will be automatically shutdown. In this case the counter (F) resets after a countdown of 20 seconds, then a message
appears (G).
In the alarm indications, the seriousness symbol can be different:
-
Alarm which does not compromise the machine operation. Check/replace the component which caused the alarm.
-
Serious alarm which does not cause the machine shutdown. Follow the relevant procedure to repair the fault.
-
STOP
Serious alarms which causes the machine shutdown. Follow the relevant procedure to repair the fault.
The alarms recognized and shown on the display (82) are shown below:
–
Fuel level sensor short-circuited (I)
–
Open fuel level sensor (J)
–
Engine coolant overtemperature (K) (the engine is automatically shut-off)
–
Engine oil low pressure (L) (the engine is automatically shut-off)
–
Hydraulic system oil low level (M)
–
Open or disconnected engine coolant temperature sensor (N)
–
Coolant temperature sensor short-circuited (H)
–
Open or disconnected engine oil pressure sensor (O)
The above-mentioned alarms are also indicated by the activation of the relevant warning lights shown in “Description of the control
area” paragraph, and by a continuous warning buzzer. The warning buzzer can be reset by pressing the button (41) on “SEL” for
several seconds.
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CONTROL PANEL DISPLAY FUNCTIONS (Continues)
B
G
D
C
A
%
E
F
K
H
L
N
O
J
M
I
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CONTROL PANEL DISPLAY FUNCTIONS (Continues)
4.
Machine memory visualization
CAUTION!
This reading and/or check must be performed with the machine stopped, in order not to distract attention
from driving.
When the key is turned to ON and the machine is stopped, it is possible to check the data about the machine condition by
performing:
• Consultation of maintenance intervals, in “MAIN MENU” on the display (82). To do this, repeatedly press the pushbutton (41) in the “STORE” position until the above-mentioned item appears. Confirm by pressing the push-button (41) in
the “SEL” position. The arrow cursor (A) will be placed near the word “STATUS”. Press the push-button (41) in the “SEL”
position again to bring the arrow cursor near the word “MAINTENANCE”. Confirm by pressing the push-button (41) in the
“STORE” position. On the display (82) the page “MAINT.01” will be displayed. The number of hours (B) indicates how many
hours there are before maintenance MA_0 will expire (200 hours), while the number of hours (C) indicates how many hours
there are before maintenance MA_1 will expire (800 hours). By pressing the push-button (41) in the “STORE” position
again, the display (82) will show the page “MAINT.02”. The number of hours (D) indicates the diesel engine running hours,
the number of hours (E) indicates the machine working hours, while the number (F) indicates the alarms occurred after the
last system reset.
• Consultation of ALARM LIST, in “MAIN MENU” on the display (82). To do this, repeatedly press the push-button (41)
in the “STORE” position until the above-mentioned item appears. Confirm by pressing the push-button (41) in the “SEL”
position. The arrow cursor (A) will be placed near the word “STATUS”. Press the push-button (41) in the “SEL” position
again to bring the arrow cursor near the word “DIAGNOSTIC”. Confirm by pressing the push-button (41) in the “STORE”
position. On the display (82) the page “ALARM_L.01” is shown. By pressing the upper part of the push-button (41) again,
the page “ALARM_L.02” will be shown. These two pages contains the alarms shown in “Alarm description” paragraph. The
numbers (G, H and I) indicates how many times the alarm occurred. If one of these numbers is different from zero, it is
possible to check when the malfunction occurred. Press the push-button (41) in the “SEL” position until the arrow cursor (J)
is placed near the required data. By pressing the push-button (41) in the “STORE” position again, the page of the required
alarm will be shown. For example, the screen (K) shows the “engine coolant overtemperature” alarm occurred for the first
time after 500 hours, and the second time after 5,550 hours.
• Consultation of B_BOX (F), where all the alarms occurred after the last memory reset are stored. The alarm is identified
by a number code that can be displayed as shown below: repeatedly press the “STORE” part of the push-button (41)
until “MAIN MENU” appears. Confirm by pressing the push-button (41) in the “SEL” position. The arrow cursor (A) will be
placed near the word “STATUS”. Press the “SEL” part of the push-button (41) again to bring the arrow cursor near the
word “MAINTENANCE”. Confirm by pressing the push-button (41) in the “STORE” position. On the display (82) the page
“MAINT.01” is shown; when pressing the “STORE” part of the push-button (41) again, the page “MAINT.02” is shown. When
pressing the “SEL” part of the push-button (41), the cursor aligns with B_BOX, then enter the B_BOX by pressing the
“STORE” part of the push-button (41). In this page, the first series of numbers (M) indicates the alarm identification number,
while the second series of numbers (N) indicates the time at which the alarm occurred. The stored alarms are up to 16
displayed on four pages, which can be scrolled by pressing the push-button (41) repeatedly.
CAUTION!
In the B_BOX the alarms are stored one after the other, so when the alarms are detected, always check
for the time at which the alarm occurred to have a real chronology of the alarms.
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IMPIANTO ELETTRICO
CONTROL PANEL DISPLAY FUNCTIONS (Continues)
A
N
M
D
E
B
C
F
J
G
H
J
I
K
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CONTROL PANEL DISPLAY FUNCTIONS (Continues)
5.
Maintenance interval reset
The Service Center must reset the maintenance intervals at 200 hours (MA_0) and 800 hours (MA_1) on the display, as shown
below:
• Press and hold the display scroll button (41) on the “STORE” position then turn the ignition key (76) to the first position.
• Press and hold the display scroll button (41) for a few seconds until the password entering screen (A) is shown.
• Insert the password 376 by pressing the push-button (41) on the “SEL” position to increase the number and on the
“STORE” position to shift the cursor to the next digit. When the number 376 is set, press and hold the push-button (41) on
the “STORE” position until the first screen is shown.
• Proceed as shown in the previous paragraph until the MAINT.01 is shown.
• Press the push-button (41) on the “SEL” position to shift the cursor (B) to the maintenance interval which has to be reset (C
or D).
NOTE
The pencil shaped cursor indicates the possibility to modify.
•
Press and hold the push-button (41) on the “STORE” position until the value returns to 200 or 800 hours, depending on the
maintenance which has been performed.
B
A
PASSWORD
C
D
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Nilfisk-Advance, Inc.
14600 21st Avenue North
Plymouth, MN, 55447-3408
www.nilfisk-advance.com
Phone: 800-989-2235
Fax: 800-989-6566
©2009 Nilfisk-Advance, Inc.,
Plymouth, MN 55447-3408
Printed in Hungary
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