Nilfisk-Advance RS 501 Manual de usuario

RS 501

ENGLISH SERVICE MANUAL

33015499(3)2008-02

SERVICE MANUAL ENGLISH

RS 501 33015500(3)2008-02 1

TABLE OF CONTENTS

GENERAL INFORMATION .............................................................................................................................................. 3

MACHINE LIFTING ......................................................................................................................................................................... 3

MACHINE TRANSPORT ................................................................................................................................................................. 3

PUSHING OR TOWING THE MACHINE......................................................................................................................................... 3

OTHER AVAILABLE MANUALS ...................................................................................................................................................... 3

SAFETY........................................................................................................................................................................................... 3

GENERAL SAFETY INSTRUCTIONS............................................................................................................................................. 4

TECHNICAL DATA........................................................................................................................................................................... 6

ENVIRONMENTAL CONDITIONS................................................................................................................................................... 8

MAINTENANCE............................................................................................................................................................................... 9

SCHEDULED MAINTENANCE TABLE ........................................................................................................................................... 9

MACHINE NOMENCLATURE ........................................................................................................................................................11

SWEEPING SYSTEM .................................................................................................................................................... 17

DESCRIPTION .............................................................................................................................................................................. 17

TROUBLESHOOTING................................................................................................................................................................... 18

SIDE BROOM POSITION CHECK AND ADJUSTMENT............................................................................................................... 19

BROOM REPLACEMENT ............................................................................................................................................................. 21

BROOM SPEED ADJUSTMENT ................................................................................................................................................... 22

DUST AND DEBRIS COLLECTION SYSTEM .............................................................................................................. 23

DESCRIPTION .............................................................................................................................................................................. 23

TROUBLESHOOTING................................................................................................................................................................... 25

HOPPER, FILTER AND SUCTION HOSE CLEANING, AND GASKET CHECK........................................................................... 26

SUCTION INLET AND SKIRT HEIGHT AND OPERATION CHECK ............................................................................................. 29

SUCTION INLET WHEEL DISASSEMBLY/ASSEMBLY................................................................................................................ 31

SUCTION INLET SLIDING PANELS DISASSEMBLY/ASSEMBLY............................................................................................... 32

SUCTION INLET DISASSEMBLY/ASSEMBLY ............................................................................................................................. 33

SKIRT REPLACEMENT ................................................................................................................................................................ 34

HOPPER POSITION ADJUSTMENT............................................................................................................................................. 35

HOPPER LID CLOSING ACTUATOR ADJUSTMENT................................................................................................................... 37

MOTOR AND SUCTION FAN DISASSEMBLY/ASSEMBLY.......................................................................................................... 39

SUCTION HOSE DISASSEMBLY/ASSEMBLY ............................................................................................................................. 41

DUST CONTROL SYSTEM ........................................................................................................................................... 43

DESCRIPTION .............................................................................................................................................................................. 43

TROUBLESHOOTING................................................................................................................................................................... 44

NOZZLE AND FILTER CLEANING................................................................................................................................................ 45

WATER FILTER CLEANING.......................................................................................................................................................... 47

WATER TANK EMPTYING ............................................................................................................................................................ 48

STEERING SYSTEM ..................................................................................................................................................... 49

DESCRIPTION .............................................................................................................................................................................. 49

TROUBLESHOOTING................................................................................................................................................................... 50

REAR AXLE TOE-IN ADJUSTMENT............................................................................................................................................. 51

BRAKE SYSTEM ........................................................................................................................................................... 53

DESCRIPTION .............................................................................................................................................................................. 53

TROUBLESHOOTING................................................................................................................................................................... 54

BRAKE FLUID LEVEL CHECK...................................................................................................................................................... 55

PARKING BRAKE CHECK AND ADJUSTMENT........................................................................................................................... 56

PARKING BRAKE CONTROL CABLE REPLACEMENT............................................................................................................... 57

BRAKE SYSTEM CHECK ............................................................................................................................................................. 59

BRAKING MASSES REPLACEMENT........................................................................................................................................... 60

BRAKE SYSTEM BLEEDING........................................................................................................................................................ 61

DRIVE SYSTEM............................................................................................................................................................. 63

DESCRIPTION .............................................................................................................................................................................. 63

TROUBLESHOOTING................................................................................................................................................................... 64

TIRE PRESSURE CHECK ............................................................................................................................................................ 65

REVERSE GEAR BUZZER CHECK AND REVERSE GEAR BUZZER ACTIVATION SENSOR ADJUSTMENT ......................... 66

REVERSE GEAR BUZZER SENSOR DISASSEMBLY/ASSEMBLY............................................................................................. 67

WHEEL REMOVAL/INSTALLATION.............................................................................................................................................. 68

DRIVE SYSTEM MOTOR DISASSEMBLY/ASSEMBLY................................................................................................................ 69

DRIVE PEDAL CHECK AND ADJUSTMENT ................................................................................................................................ 70

ENGLISH SERVICE MANUAL

233015500(3)2008-02 RS 501

LDW 1603/B2 ENGINE.................................................................................................................................................. 73

DESCRIPTION .............................................................................................................................................................................. 73

TROUBLESHOOTING................................................................................................................................................................... 74

ENGINE OIL LEVEL CHECK......................................................................................................................................................... 75

ENGINE OIL CHANGE .................................................................................................................................................................. 76

ENGINE OIL FILTER CHANGE..................................................................................................................................................... 77

ENGINE COOLANT LEVEL CHECK ............................................................................................................................................. 78

ENGINE AIR FILTER CLEANING.................................................................................................................................................. 79

FUEL FILTER REPLACEMENT..................................................................................................................................................... 80

FUEL FITTING AND SCREW CHECK .......................................................................................................................................... 81

ALTERNATOR BELT TENSION CHECK....................................................................................................................................... 82

ALTERNATOR BELT REPLACEMENT.......................................................................................................................................... 83

RADIATOR FIN CLEANING CHECK............................................................................................................................................. 84

ENGINE COOLANT LINE SLEEVE CHECK ................................................................................................................................. 85

ENGINE COOLANT CHANGE ...................................................................................................................................................... 86

INJECTOR CALIBRATION AND CLEANING ................................................................................................................................ 87

CLIMATE CONTROL SYSTEM ..................................................................................................................................... 89

DESCRIPTION .............................................................................................................................................................................. 89

TROUBLESHOOTING................................................................................................................................................................... 90

COMPRESSOR BELT TENSION CHECK (LDW 1603/B2 engine)............................................................................................... 91

COMPRESSOR BELT REPLACEMENT (LDW 1603/B2 engine).................................................................................................. 92

AIR FILTER REPLACEMENT........................................................................................................................................................ 93

OTHER SYSTEMS......................................................................................................................................................... 95

NUT AND SCREW TIGHTENING AND LEAKAGE CHECK.......................................................................................................... 95

LUBRICATION............................................................................................................................................................................... 96

CHECK AND ADJUSTMENT OF SENSOR FOR ENGINE START-UP INHIBITION WHEN

THE DRIVE PEDAL IS PRESSED ................................................................................................................................................ 97

DISASSEMBLY/ASSEMBLY OF SENSOR FOR ENGINE START-UP INHIBITION WHEN

THE DRIVE PEDAL IS PRESSED ................................................................................................................................................ 98

HYDRAULIC SYSTEM................................................................................................................................................... 99

DESCRIPTION .............................................................................................................................................................................. 99

COMPONENT LOCATION ............................................................................................................................................................ 99

HYDRAULIC DIAGRAM .............................................................................................................................................................. 101

TROUBLESHOOTING................................................................................................................................................................. 103

HYDRAULIC SYSTEM OIL LEVEL AND DRAIN FILTER EFFICIENCY CHECK........................................................................ 104

HYDRAULIC SYSTEM OIL CHANGE ......................................................................................................................................... 105

HYDRAULIC SYSTEM OIL SUCTION FILTER REPLACEMENT ............................................................................................... 107

HYDRAULIC SYSTEM OIL DRAIN FILTER REPLACEMENT .................................................................................................... 108

DRIVE SYSTEM PUMP OIL FILTER REPLACEMENT............................................................................................................... 109

HYDRAULIC SYSTEM OIL COOLER FIN CLEANING CHECK...................................................................................................110

REAR WHEEL CONTROL HYDRAULIC CYLINDER DISASSEMBLY/ASSEMBLY.....................................................................111

HYDRAULIC CYLINDERS DISASSEMBLY/ASSEMBLY ............................................................................................................112

SUCTION FAN CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION...............................................................................114

ACCESSORY SYSTEM CONTROL VALVE ASSEMBLY REMOVAL/INSTALLATION.................................................................115

ACCESSORY AND STEERING SYSTEM PUMP DISASSEMBLY/ASSEMBLY (LDW 1603/B2 engine).....................................116

SUCTION FAN PUMP DISASSEMBLY/ASSEMBLY .................................................................................................................. 120

DRIVE SYSTEM PUMP DISASSEMBLY/ASSEMBLY................................................................................................................. 121

HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE SUCTION FAN PUMP ..................................................................... 122

HYDRAULIC SYSTEM OIL PRESSURE CHECK AT THE ACCESSORY AND STEERING SYSTEM PUMP............................ 124

HYDRAULIC SYSTEM OIL PRESSURE CHECK ON DRIVE SYSTEM PUMP.......................................................................... 126

ELECTRICAL SYSTEM ............................................................................................................................................... 129

DESCRIPTION ............................................................................................................................................................................ 129

COMPONENT LOCATION .......................................................................................................................................................... 129

WIRING DIAGRAM...................................................................................................................................................................... 133

TROUBLESHOOTING................................................................................................................................................................. 137

BATTERY FLUID LEVEL CHECK................................................................................................................................................ 138

FUSE REPLACEMENT ............................................................................................................................................................... 139

RELAY REPLACEMENT ............................................................................................................................................................. 140

CONTROL PANEL DISPLAY REPLACEMENT ........................................................................................................................... 141

LOW BEAM AND HIGH BEAM ADJUSTMENT AND BULB REPLACEMENT ............................................................................ 142

SERVICE MANUAL ENGLISH

RS 501 33015500(3)2008-02 3

GENERAL INFORMATION

NOTE

Forward, backward, front, rear, left or right are intended with reference to the operator’s position, while on the driver’s

seat.

MACHINE LIFTING

WARNING!

Do not work under the lifted machine without supporting it with safety stands.

MACHINE TRANSPORT

(See User Manual)

WARNING!

Before transporting the machine, make sure that:

All lids and covers are closed.

All moving parts are stopped.

The ignition key is removed.

The machine is securely fastened to the means of transport.

–

PUSHING OR TOWING THE MACHINE

WARNING!

When pushing or towing the machine, carefully follow the relevant instructions given in the User Manual. Failure

to follow these instructions may cause damage to the machine.

OTHER AVAILABLE MANUALS

The following Manuals are available at Nilﬁsk Literature Service Department:

RS 501 Spare Parts List – Nilﬁsk Form Number 33015502

RS 501 User Manual – Nilﬁsk Form Number 33015501

SAFETY

The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary

precautions to safeguard people and property.

DANGER!

It indicates a dangerous situation with risk of death for the operator.

WARNING!

It indicates a potential risk of injury for people or damage to objects.

CAUTION!

It indicates a caution related to important or useful functions.

Pay careful attention to the paragraphs marked by this symbol.

NOTE

It indicates a remark related to important or useful functions.

CONSULTATION

It indicates that it is necessary to consult the User Manual before performing any procedure.

–

ENGLISH SERVICE MANUAL

433015500(3)2008-02 RS 501

GENERAL INFORMATION

GENERAL SAFETY INSTRUCTIONS

Speciﬁc warnings and cautions to inform about potential damages to people and machine are shown below.

DANGER!

This machine must be used by properly trained and authorised personnel only.

Moreover, the operator must:

Be of full age

Have a driving license

Be in normal psycho-physical conditions

Not be under the effect of substances that alters the nervous system (alcohol, psycopharmaceuticals,

drugs, etc.)

Before performing any maintenance/repair procedure remove the ignition key, engage the parking brake

and disconnect the battery.

Do not wear jewels when working near electrical components.

Do not work under the lifted machine without supporting it with safety stands.

When working under open hoods/lids, make sure that they cannot be closed by accident.

When performing maintenance procedures with the lifted hopper, apply the relevant support rods.

Do not operate the machine near toxic, dangerous, ﬂammable and/or explosive powders, liquids or vapors.

Be careful, fuel is highly ﬂammable.

Do not smoke or bring naked ﬂames in the area where the machine is refuelled or where the fuel is stored.

Refuel outdoors or in a well-ventilated area, with the engine off.

Do not ﬁll the fuel tank to the top, but leave at least 4 cm from the ﬁller neck to allow the fuel to expand.

After refuelling, check that the ﬁller cap is tightly closed.

If any fuel is spilled while refuelling, clean up the affected area and allow the vapors to dissipate before

starting the engine.

Avoid contact with skin and do not breathe in fuel vapors. Keep out of reach of children.

Do not tilt the engine too much to avoid fuel spillage.

During machine transportation, the fuel tank must not be full.

–

•

–

WARNING!

Carbon monoxide (CO) can cause brain damage or death.

The internal combustion engine of this machine can emit carbon monoxide.

Do not inhale exhaust gas fumes.

Only use indoors when adequate ventilation is provided, and when an assistant has been instructed to look

after you.

Do not lay any object on the engine.

Before working on the engine turn it off. To prevent the engine from starting accidentally, disconnect the

battery negative terminal.

See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this

Manual.

–

SERVICE MANUAL ENGLISH

RS 501 33015500(3)2008-02 5

GENERAL INFORMATION

WARNING!

Carefully read all the instructions before performing any maintenance/repair procedure.

Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by the machine

moving parts.

Protect body parts (eyes, hair, hands, etc.) properly, when performing cleaning procedures using

compressed air or water gun.

Avoid contact with battery acid, do not touch hot parts.

Do not leave the machine unattended with the ignition key inserted and the parking brake deactivated.

Do not remove or modify the plates afﬁxed to the machine.

To drive on public roads, the machine must follow local licensing requirements.

The machine has been designed to be used as a sweeper, do not use it for different purposes.

In case of part replacement, order ORIGINAL spare parts from an authorised Dealer or Retailer.

The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries,

etc.), which are subject to standards that require disposal in special centres (see the Scrapping chapter).

While the engine is running the silencer heats up. Do not touch the silencer to avoid serious scalding or

ﬁre.

Do not run the engine if the oil level is low, to avoid damaging it seriously. Check the oil level with the

engine off and the machine on a level surface.

Do not run the engine if the air ﬁlter is not installed, to avoid damaging it.

The coolant line is pressurised; do not perform any check until the engine has cooled down and, even if the

engine is cold, the tank plug must be opened with extreme care.

Only use original spare parts or parts of matching quality for the diesel engine. Using spare parts of lower

quality can seriously damage the engine.

See also the SAFETY RULES in the Diesel Engine Manual, which is to be considered an integral part of this

Manual.

–

ENGLISH SERVICE MANUAL

633015500(3)2008-02 RS 501

GENERAL INFORMATION

TECHNICAL DATA

Dimensions and weights Values

Machine length (broom bristles not included) 3,065 mm

Machine width (broom bristles not included) 1,315 mm

Distance between front and rear wheels 1,475 mm

Front wheel base 930 mm

Rear wheel base 840 mm

Machine height 1,997 mm

Minimum distance from the ground (skirts not included) 90 mm

Maximum front working angle 18°

Maximum dumping height 1,460 mm

Front tires R165/70 R14C 89R

Rear tires R165/70 R14C 89R

Tire pressure 3.75 Bar

Standard side broom diameter 720 mm

Optional side broom diameter 650 mm

Total machine weight, in running condition (without operator) 1,500 Kg

Performance data Values

Maximum forward speed (for transport only) 20 km/h

Maximum working speed 12 km/h

Maximum reverse speed 8 km/h

Gradeability at full load 22% (30% optional)

Minimum inner turning radius 2.46 m

Maximum side broom speed 80 rpm

Collection system Suction

Cleaning width 1,600 mm

Filtering system Metallic net

Sound pressure level at workstation (ISO/EN 3744) at maximum working speed 82 dB(A)

Certiﬁed sound power (2000/14/EC) at maximum working speed 108 dB(A)

Measured sound power (ISO/EN 3744) at maximum working speed 106 dB(A)

Hopper capacity 500 liters

Hopper maximum load 380 Kg

Dust control By water

Dust control system tank total capacity (No. 2) 240 liters

Lighting and signalling system Road type

Transmission Hydrostatic servoassisted

Steering system On the rear axle, power assisted

Brake Hydraulic

Parking brake Mechanic

Controls Hydraulic

SERVICE MANUAL ENGLISH

RS 501 33015500(3)2008-02 7

GENERAL INFORMATION

LDW 1603/B2 diesel engine data (*) Values

Make Lombardini

Type LDW 1603/B2

Cylinders 3

Maximum speed 2,600 rpm

Maximum working speed 2,200 rpm

Maximum power at 2,600 rpm 25 kW

Idle speed 900 rpm

Consumption while operating at 2,200 rpm 5.0 L/h

Consumption while operating at 2,600 rpm 5.9 L/h

Engine coolant 50% antifreeze AGIP and 50% water (**)

Engine oil type AGIP Sigma Turbo 15W/40 (***)

(*) For other diesel engine data/values, see the relevant Manual.

(**) See the coolant technical data and reference data tables below.

SPECIFICATIONS REFERENCE DATA

Boiling point °C 170 CUNA NC 956-16 97

Boiling point in solution with 50% water °C 110 FF.SS cat. 002/132

Freezing point in solution with 50% water °C -38 ASTM D 1384

Color / Turquoise

blue

Density at 15°C kg/l 1.13

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

SPECIFICATIONS REFERENCE DATA

SAE QUALITY / 15W40 ACEA E3-96

Viscosity at 100°C mm2/s 13.7 API Service CG-4/SG

Viscosity at 40°C mm2/s 100 CCMC D5, PD-2

Viscosity at -15°C mm2/s 3,300 US Department of the Army MIL-L-2104 E

Viscosity index / 138 US Department of the Army MIL-L-46152 E

Flash point COC °C 230 MACK EO-L

Pour point °C -27 MAN M 3275

Density at 15°C kg/l 0.885 Mercedes Benz 228.3

VOLVO VDS2

MTU typ 2

Refuelling data Values

Fuel tank capacity 30 liters

Hydraulic system oil tank capacity 40.6 liters

Hydraulic system capacity 58 liters

Electrical system data Values

System voltage 12 V

Starting battery 12 V – 80 Ah

ENGLISH SERVICE MANUAL

833015500(3)2008-02 RS 501

GENERAL INFORMATION

Hydraulic system data Values

Maximum drive system pressure 250 Bar

Maximum accessory system pressure 120/200 Bar

Hydraulic system oil type (at ambient temperature above 10°C) AGIP Arnica 46 (****)

NOTE

If the machine is to be used at ambient temperatures below 10°C, the oil should be replaced with equivalent oil having a

viscosity of 32 cSt. For temperatures below 0°C, use oil with lower viscosity.

(****) See the below hydraulic system oil technical data and reference data tables.

TECHNICAL DATA REFERENCE DATA

AGIP ARNICA 46 32 ISO-L-HV

Viscosity at 40°C mm2/s 45 32 ISO 11158

Viscosity at 100°C mm2/s 7.97 6.40 AFNOR NF E 48603 HV

Viscosity index / 150 157 AISE 127

Flash point COC °C 215 202 ATOS Tab. P 002-0/I

Pour point °C -36 -36 BS 4231 HSE

Density at 15°C kg/l 0.87 0.865 CETOP RP 91 H HV

COMMERCIAL HYDRAULICS

Danieli Standard 0.000.001 (AGIP ARNICA

22, 46, 68)

EATON VICKERS I-286-S3

EATON VICKERS M-2950

DIN 51524 t.3 HVLP

LAMB LANDIS-CINCINNATI P68, P69 and

P70

LINDE

PARKER HANNIFIN (DENISON) HF-0

REXROTH RE 90220-1/11.02

SAUER-DANFOSS 520L0463

ENVIRONMENTAL CONDITIONS

In the environment where the machine operates, there must not be any danger of explosion.

To avoid inhaling exhaust gas, the machine must be used only where there is a proper air change.

The machine operates correctly (*) in the following environmental conditions:

Temperature: -10°C to +40°C

Humidity: 30% to 95%, not condensed

Store the machine indoor, in a clean and dry place, protected from bad weather conditions and with the following values:

Temperature: +1°C to +50°C

Humidity: maximum 95%, not condensed

(*) When using the sweeper at a temperature between -10°C and 0°C the dust control system cannot be used; moreover the

water tanks and the dust control system itself must be empty.

–

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