Terra 128B - 132B SERVICE MANUAL 146 0721 000(2)2003-04
SERVICE MANUAL INDEX GENERAL INFORMATION MACHINE LIFTING MACHINE TRANSPORTATION OTHER AVAILABLE MANUALS SAFETY - ACCIDENT PREVENTION GENERAL SAFETY RULES TECHNICAL DATA MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE MACHINE NOMENCLATURE 3 3 3 3 4 4 5 7 7 7 8 SWEEPING SYSTEM VISUAL INSPECTION OF THE BELT FROM THE ENGINE TO THE MAIN BRUSH BELT REPLACEMENT FROM THE ENGINE TO THE MAIN BRUSH MAIN BRUSH HEIGHT ADJUSTMENT MAIN BRUSH REPLACEMENT SIDE BRUSH HEIGHT ADJUSTMENT SIDE BRUSH REPLACEMENT
SERVICE MANUAL ELECTRICAL SYSTEM BATTERY MAINTENANCE AND RECHARGING BATTERY INSTALLATION AND BATTERY TYPE SETTING (WET OR GEL) FUSE REPLACEMENT ELECTRONIC BOARD REPLACEMENT HOOD SAFETY SWITCH OPERATION CHECK CHECK IF THE MACHINE DOES NOT START WHEN THE (OPTIONAL) BATTERY CHARGER PLUG IS CONNECTED TO THE NET OUTLET COMPONENT LAYOUT WIRING DIAGRAMS 44 44 44 45 46 47 47 48 50 In this manual, all the references to front part, R.H. side, L.H.
SERVICE MANUAL GENERAL INFORMATION MACHINE LIFTING GENERAL INFORMATION WARNING! Do not work under the lifted machine, if it is not securely fixed.
SERVICE MANUAL GENERAL INFORMATION SAFETY - ACCIDENT PREVENTION The following symbols indicate potentially dangerous situations. Always read carefully this information and take the necessary precautions to protect people and objects. DANGER! Indicates a dangerous situation (risk of death) for the User. WARNING! Indicates the risk of being injured. CAUTION! Indicates a caution or a remark related to important or useful functions. Take care of the paragraphs marked by this symbol.
SERVICE MANUAL GENERAL INFORMATION WARNING! – Carefully read all maintenance/repair 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. – Do not smoke during battery charging. – Do not leave the machine unattended with the ignition key inserted and the parking brake deactivated.
SERVICE MANUAL GENERAL INFORMATION Rear wheels, driving Ø 250 x 50 mm (Ø 9.84 x 1.97 in) Main electric motor 600 W - 3000 RPM Sound level (Lpa) 64 dB (A) Electric filter-shaker (optional) 12 V, 30 W Batteries Terra 128B Terra 132B Standard battery Lead, with acid electrolyte (WET) Optional battery Gel, hermetic (GEL) Battery voltage 12 V Battery compartment max. size 398x262x283 (15.7x10.3x11.
SERVICE MANUAL GENERAL INFORMATION MAINTENANCE SCHEDULED MAINTENANCE The machine proper and safe operation is granted by a careful and constant maintenance. See GENERAL INFORMATION and SAFETY - ACCIDENT PREVENTION The following table sums up the scheduled maintenance. The indicated periods can be subjected to variations according to working conditions. These must be defined by the person in charge of maintenance. For maintenance operation instructions see the following paragraphs.
SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE In this Manual you find numbers in brackets – example: (2). These numbers refer to the components indicated in these two nomenclature pages. Refer to these pages each time you want to find the 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.
SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (CONTINUES) S300367 146 0721 000(2)2003-04 9
SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (CONTINUES) S300368 10 146 0721 000(2)2003-04
SERVICE MANUAL SWEEPING SYSTEM VISUAL INSPECTION OF THE BELT FROM THE ENGINE TO THE MAIN BRUSH SWEEPING SYSTEM 1. 2. 3. 4. 5. 6. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Visually inspect the timing belt (47) condition from the engine to the main brush. To check the belt completely, rotate is by operating manually on the fan (51).
SERVICE MANUAL SWEEPING SYSTEM MAIN BRUSH HEIGHT ADJUSTMENT Remark: Brushes with harder or softer bristles are available. This procedure is applicable to each type of brushes. Check 1. Check the main brush correct height from the ground, proceeding as follows: – Drive the machine on a level ground. – Keep the machine stationary and rotate the main brush for a few seconds. – Stop the main brush and move the machine. – Check that the main brush print (A), along is width, is from 0.8 to 1.6 in (2 to 4 cm).
SERVICE MANUAL SWEEPING SYSTEM MAIN BRUSH REPLACEMENT Remark: Brushes with harder or softer bristles are available. This procedure is applicable to each type of brushes. CAUTION! It is advisable to use protective gloves when replacing the main brush because there can be cutting debris between the bristles. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position.
SERVICE MANUAL SWEEPING SYSTEM SIDE BRUSH HEIGHT ADJUSTMENT Remark: Brushes with harder or softer bristles are available. This procedure is applicable to each type of brushes. Check 1. Check the side brush correct height from the ground, proceeding as follows: – Drive the machine on a level ground and lower the side brush. – Keep the machine stationary and rotate the side brush for few seconds. – Stop the side brush and move the machine.
SERVICE MANUAL SWEEPING SYSTEM SIDE BRUSH REPLACEMENT Remark: Brushes with harder or softer bristles are available. This procedure is applicable to each type of brushes. CAUTION! It is advisable to use protective gloves when replacing the side brush because there can be cutting debris between the bristles. 1. 2. 3. 4. Turn the ignition key (2) to “0” position. Insert the hand inside the side brush and press the tabs (A) inward and then remove the brush (B) disengaging it from the four pins (C).
SERVICE MANUAL SWEEPING SYSTEM MAIN MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. Discharged motor electrical input check 1. 2. Remove the main brush (see the procedure in the related paragraph). Open the hood (16). WARNING! Carry out the following operation with extreme care. 3. 4. 5. 6. 7. 16 Set an ammeter (A) on the battery positive cable (B). Remove the side brush motor fuse (42).
SERVICE MANUAL SWEEPING SYSTEM Charged motor electrical input check 8. 9. 10. 11. Reinstall the main brush (see the procedure in the related paragraph). Check that the main brush height adjustment is correct (see the procedure in the related paragraph). Warm up the main electric motor by operating the machine for at least ten minutes. Open the hood (16). WARNING! Carry out the following operation with extreme care. 12. Set an ammeter (A) on the battery positive cable (B). 13.
SERVICE MANUAL SWEEPING SYSTEM MAIN MOTOR BRUSH/CARBON BRUSH CHECK AND REPLACEMENT 1. 2. 3. 4. 5. 6. 7. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Disconnect the battery electrical connector (38) and remove the batteries (37) and the related holder. Remove dust and dirt from the motor exterior part; then disengage and remove the clamp (A).
SERVICE MANUAL SWEEPING SYSTEM MAIN BRUSH AND REDUCTION UNIT REPLACEMENT Removal 1. 2. 3. 4. 5. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Disconnect the battery electrical connector (38). Remove the belt (47) from the pulley (49). To facilitate the operation, rotate the pulley (49) by manually operating on the fan (51). 6. Remove the belt (48) from the pulley (50). 7.
SERVICE MANUAL SWEEPING SYSTEM MAIN BRUSH AND REDUCTION UNIT REPLACEMENT (Continues) Figure 15 S300374 20 146 0721 000(2)2003-04
SERVICE MANUAL SWEEPING SYSTEM MAIN BRUSH AND REDUCTION UNIT REPLACEMENT (Continues) Figure 16 S300375 146 0721 000(2)2003-04 21
SERVICE MANUAL SWEEPING SYSTEM SIDE BRUSH MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. 1. 2. Remove the side brush (see the procedure in the related paragraph). Remove the screws (9) and lift the control panel (1). WARNING! Carry out the following operation with extreme care. 3. 4. 5. Turn the ignition key (2) to "I" position, without pulling the selector lever (13).
SERVICE MANUAL SWEEPING SYSTEM SIDE BRUSH MOTOR REPLACEMENT 1. Remove the battery (37) and the related holder. WARNING! If you do not remove the batteries before inclining the machine, serious damages to people or the machine can occur. 2. Operating on the handles (14), lower the handlebar (12) as shown in the figure below, then carefully lower the machine at the back (as shown in the figure below). 3. Remove the side brush (A). 4. Remove the screw (B). 5. Remove the hub (C) and recover the key (D). 6.
SERVICE MANUAL SWEEPING SYSTEM TROUBLESHOOTING THE MACHINE DOES NOT START with the key (2) to "I" position (the control panel does not activate). Possible cause: 1. The battery connector (38) is not correctly connected (connect it) 2. The hood (16) is not correctly closed (close it) 3. The battery is discharged (charge it) 4. Possible disconnection of an electrical cable under the control panel (1) (disconnect the battery and connect the cable) 5.
SERVICE MANUAL FLAP FLAP HEIGHT AND OPERATION CHECK (AND ADJUSTMENT) FLAP 1. 2. 3. Drive the machine on a level and adequate ground to check the flap height. Activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Side flap check 4. 5. Check the side flap (23 and 24) integrity. Replace the flaps when they have cuts (A) larger than 20 mm or cracks (B) larger than 10 mm (see the “Service Manual” for Flap Replacement).
SERVICE MANUAL FLAP FLAP HEIGHT AND OPERATION CHECK (AND ADJUSTMENT) (continues) Figure 4 Figure 3 S300249 S300248 Figure 6 Figure 5 P P M N S300251 S300250 Figure 8 Figure 7 S300376 26 S300377 146 0721 000(2)2003-04
SERVICE MANUAL FLAP SIDE FLAP REPLACEMENT 1. 2. 3. Drive the machine on a level and adequate ground to check the flap height. Activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Left flap 4. Loosen the knob (A) and remove the brush left cover (B) by pulling outward to disengage the retainers (C). 5. Remove the screws (D) the straps (E) and the rear flap (F). 6. Reinstall the new rear flap (F) with the straps (E) and the screws (D). 7.
SERVICE MANUAL FLAP FRONT AND REAR FLAP REPLACEMENT 1. 2. 3. 4. 5. Drive the machine on a level and adequate ground to check the flap height. Activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Remove the main brush, as described in the related paragraph. (Only for Terra 132B) Lightly lift the front side of the machine.
SERVICE MANUAL FLAP FRONT FLAP LIFTING CABLE ADJUSTMENT (only for Terra 132B) Correct adjustment check 1. 2. 3. 4. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to "0" position. Remove the main brush, as described in the related paragraph.
SERVICE MANUAL FLAP FRONT FLAP LIFTING CABLE ADJUSTMENT (only for Terra 132B) (continues) Figure 14 S300380 Figure 15 S300381 30 146 0721 000(2)2003-04
SERVICE MANUAL FLAP FRONT FLAP LIFTING CABLE REPLACEMENT (only for Terra 132B) 1. 2. 3. 4. 5. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to "0" position. Remove the hopper (27). Open the hood (16). Remove the battery (37). WARNING! If you do not remove the batteries before inclining the machine, serious damages to people or the machine can occur. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Close the hood (16).
SERVICE MANUAL FLAP FRONT FLAP LIFTING CABLE REPLACEMENT (only for Terra 132B) (continues) Figure 17 S300383 32 146 0721 000(2)2003-04
SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM DUST FILTER CLEANING AND INTEGRITY CHECK DUST AND DEBRIS COLLECTION SYSTEM Remark: Besides the standard paper filter, optional polyester filters are also available. The following procedure is applicable to each type. 1. 2. 3. 4. 5. 6. 7. 8. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Disengage the retainer (28) By means of the handle (29) pull out the hopper (17).
SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM FILTER-SHAKER OPERATION CHECK 1. 2. While using the machine, when the panel filter is supposed to be full, activate the filter-shaker proceeding as follows, according to the type of filter-shaker installed: – Manual filter-shaker: Pull the handle (30) outward up to the end of stroke, then release it: the interior return spring strikes the dust filter frame and shakes it. Repeat this operation several times.
SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM TROUBLESHOOTING THE SUCTION SYSTEM (FAN) DOES NOT ROTATE Possible cause: 1. The battery is discharged (charge the battery). 2. The electric motor brushes are worn (replace them). 3. Main electric motor failure (repair or replace it) 4. Foreign materials obstruct the fan (remove them). 5. The wiring harness is damaged (repair it). 6.
SERVICE MANUAL TRACTION SYSTEM DRIVING BELT VISUAL INSPECTION TRACTION SYSTEM 1. 2. 3. 4. 5. 6. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Visually inspect the driving belt (48) condition. Check the belt completely by turning it manually one full turn. If the belt is worn, replace it according to the procedure indicated in the related paragraph. Carry out steps from 1. to 3. in the reverse order.
SERVICE MANUAL TRACTION SYSTEM DRIVING BELT CONTROL CABLE REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Remove the clip (A) and move the fork (B) of the driving belt control cable. Unscrew the terminal (C) and remove it. Pull out the cable (D) by pulling it from the side of the selector lever. If necessary, remove the sheath (E) (see the procedure on the following page).
SERVICE MANUAL TRACTION SYSTEM DRIVING BELT CONTROL CABLE SHEATH REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the driving belt control cable (see the procedure on the previous page). Turn the ignition key (2) to “0” position. Open the hood (16). Unscrew the nut (A) fixing the sheath on the tensor side. Connect a probe (cord or equivalent) to the sheath end (B) (this operation is necessary to facilitate the insertion of the sheath inside the carter). Disengage the clip (C) from the sheath.
SERVICE MANUAL TRACTION SYSTEM DRIVING BELT REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Remove the hopper (27). Open the hood (16). Remove the belt (48) from the pulley (50). Remove the screws (A) fixing the axle to the frame, on machine both sides. Lightly lift the machine and detach the axle with the wheels (B). Recover the driving belt (C). Install in the reverse order of removal.
SERVICE MANUAL TRACTION SYSTEM DRIVING WHEEL OR AXLE BEARING REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Remove the hopper (27). Open the hood (16). Remove the belt (48) from the pulley (50). Remove the screws (M) fixing the axle to the frame, on machine both sides. Lightly lift the machine and detach the axle with the wheels (N). Recover the driving belt (O).
SERVICE MANUAL TRACTION SYSTEM DRIVING WHEEL OR AXLE BEARING REPLACEMENT (continues) Figure 8 S300267 Figure 9 S300268 146 0721 000(2)2003-04 41
SERVICE MANUAL TRACTION SYSTEM TROUBLESHOOTING THE MACHINE DOES NOT MOVE Possible cause: 1. Dust or foreign materials rolled up between the transmission elements (remove them) 2. The selector lever control cable is misadjusted or broken (adjust/replace it) 3. The driving belt (48) is broken (replace it) 4. The brake (36) is activated (deactivate it). 5. The wheel bearings do not set on the traction shaft (adjust them by means of the related dowel pins).
SERVICE MANUAL OTHER SYSTEMS SCREW AND NUT TIGHTENING CHECK OTHER SYSTEMS 1. 2. 3. 4. 5. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Remove the hopper (27). Open the hood (16). Remove the battery (37). WARNING! If you do not remove the batteries before inclining the machine, serious damages to people or the machine can occur. 6.
SERVICE MANUAL ELECTRICAL SYSTEM BATTERY MAINTENANCE AND RECHARGING ELECTRICAL SYSTEM See Use and Maintenance Manual BATTERY INSTALLATION AND BATTERY TYPE SETTING (WET OR GEL) Battery type selection 1. 2. 3. The machine can be equipped with the following types of batteries: – Lead battery, with acid electrolyte – Gel battery, hermetic To identify battery voltage and capacity, see chapter Technical Data. To assemble the battery on the machine, see the diagram (45). Battery removal 4. 5. 6. 7. 8.
SERVICE MANUAL ELECTRICAL SYSTEM FUSE REPLACEMENT 1. 2. 3. 4. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Disconnect the battery electrical connector (38). 60 A fuse (main fuse) replacement 5. Remove the guard (41) and pull out the underlying 60 A fuse. 15 A fuse (side brush motor fuse) replacement 6. Pull out the 15 A fuse (42). 10 A fuse replacement (Key-electronic board fuse) 7.
SERVICE MANUAL ELECTRICAL SYSTEM ELECTRONIC BOARD REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. Drive the machine on a level ground and activate the pedal brake (36), if present. Turn the ignition key (2) to “0” position. Open the hood (16). Disconnect the battery electrical connector (38). Remove the screws (9) and lift the control panel (1). Disconnect the electrical connector (A). Remove the electronic board (B) by disconnecting the screws (C).
SERVICE MANUAL ELECTRICAL SYSTEM HOOD SAFETY SWITCH OPERATION CHECK 1. 2. 3. 4. 5. 6. 7. With the machine off, open the hood (16). Try to start the machine by turning the ignition key (2) to "I" position and check that it is not possible to start the machine. Close the hood (16). Start the machine by turning the ignition key (2) to "I" position. Open the hood (16) and check that the machine turns off immediately. Turn the ignition key (2) to "O" position. Close the hood (16).
SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LAYOUT Remark: The symbol in brackets (..) after the name of the component refers to the wiring diagram (see the following pages). 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
SERVICE MANUAL ELECTRICAL SYSTEM Figure 3 S300385 146 0721 000(2)2003-04 49
SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAMS Wiring diagrams for optional equipments: 1. Standard 2.
SERVICE MANUAL ELECTRICAL SYSTEM CN2 SW2 BN F3 SW1 WH WH OG CH1 STANDARD OG BU BK RD RD CN1 RD F1 ES1 RD + GY EB1 + BATTERIES 12V GY M2 - F2 V- BK BK CN1 CN2 Gel Pb RD M1 BK Out V+ BK SW2 BN F3 SW1 SW3 WH WH OG BK BN CH1 R1 OG RD M3 BK WITH SHAKER OG YE BU BK RD RD CN1 RD F1 ES1 RD + GY EB1 + BATTERIES 12V M2 - GY F2 V- BK BK BK CN1 M1 Out V+ Gel Pb RD BK BK S300416 146 0721 000(2)2003-04 51
SERVICE MANUAL ELECTRICAL SYSTEM 52 146 0721 000(2)2003-04
Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 ©2003 Nilfisk-Advance, Inc.
