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TerraTM 3700B

SERVICE MANUAL Advance model: 908 4203 010

146 1965 000(2)2007-02

ENGLISH

SERVICE MANUAL

146 1965 000(2)2007-02

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SERVICE MANUAL

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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 PRECAUTIONS .................................................................................................................... 4 TECHNICAL DATA ................................................................................................................................................. 5 MAINTENANCE ..................................................................................................................................................... 6 SCHEDULED MAINTENANCE TABLE .................................................................................................................. 6 MACHINE NOMENCLATURE ................................................................................................................................ 7 MACHINE NOMENCLATURE [for machines up to serial number 062211246] . .................................................... 8 MACHINE NOMENCLATURE [for machines from serial number 062211247] .................................................... 10 SWEEPING SYSTEM ............................................................................................................................................... 12 MOTOR-TO-MAIN BROOM BELT CHECK .......................................................................................................... 12 MOTOR-TO-MAIN BROOM BELT REPLACEMENT ........................................................................................... 12 MAIN BROOM HEIGHT CHECK AND ADJUSTMENT ........................................................................................ 13 MAIN BROOM REPLACEMENT .......................................................................................................................... 14 SIDE BROOM HEIGHT CHECK AND ADJUSTMENT ......................................................................................... 15 SIDE BROOM REPLACEMENT .......................................................................................................................... 17 MAIN MOTOR ELECTRICAL INPUT CHECK . .................................................................................................... 18 STARTER/DYNAMO OR MAIN MOTOR CARBON BRUSH CHECK AND REPLACEMENT ............................. 19 MAIN MOTOR AND REDUCTION UNIT REMOVAL/INSTALLATION ................................................................. 20 STARTER/DYNAMO AND REDUCTION UNIT REMOVAL/INSTALLATION ....................................................... 22 SIDE BROOM MOTOR ELECTRICAL INPUT CHECK . ...................................................................................... 24 SIDE BROOM MOTOR REMOVAL/INSTALLATION . .......................................................................................... 25 SIDE BROOM LIFTING CABLE REPLACEMENT [for machines from serial number 062211247] ..................................................................................................... 26 SIDE BROOM MICROSWITCH ADJUSTMENT/REPLACEMENT [for machines from serial number 062211247] ..................................................................................................... 27 TROUBLESHOOTING ......................................................................................................................................... 28 SKIRT . ...................................................................................................................................................................... 29 SKIRT HEIGHT AND OPERATION CHECK ........................................................................................................ 29 SIDE SKIRT REPLACEMENT ............................................................................................................................. 31 FRONT AND REAR SKIRT REPLACEMENT ...................................................................................................... 32 FRONT SKIRT LIFTING CABLE ADJUSTMENT ................................................................................................. 33 FRONT SKIRT LIFTING CABLE REPLACEMENT .............................................................................................. 34 DUST AND DEBRIS COLLECTION SYSTEM ......................................................................................................... 35 DUST FILTER CLEANING AND INTEGRITY CHECK ......................................................................................... 35 FILTER SHAKER OPERATION CHECK .............................................................................................................. 36 FILTER SHAKER MOTOR ELECTRICAL INPUT CHECK . ................................................................................. 36 TROUBLESHOOTING ......................................................................................................................................... 36 MANUAL VACUUM SYSTEM . ................................................................................................................................. 37 MANUAL VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT ................................ 37 MANUAL VACUUM SYSTEM MOTOR REMOVAL/INSTALLATION . .................................................................. 38 TROUBLESHOOTING ......................................................................................................................................... 38

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BRAKE SYSTEM ...................................................................................................................................................... 39 BRAKE ADJUSTMENT [for machines up to serial number 062211246] .............................................................. 39 BRAKE ADJUSTMENT [for machines from serial number 062211247] ............................................................... 41 BRAKE REPLACEMENT [for machines up to serial number 062211246] ........................................................... 42 BRAKE REPLACEMENT [for machines from serial number 062211247] ............................................................ 43 DRIVE SYSTEM . ...................................................................................................................................................... 44 DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK .................................................................................... 44 DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT .................................................... 45 DRIVE SYSTEM MOTOR REMOVAL/INSTALLATION ........................................................................................ 46 DRIVE PEDAL CHECK AND ADJUSTMENT . ..................................................................................................... 47 TROUBLESHOOTING ......................................................................................................................................... 48 OTHER SYSTEMS . .................................................................................................................................................. 49 SCREW AND NUT TIGHTENING CHECK .......................................................................................................... 49 FRONT COVER DISASSEMBLY/ASSEMBLY[for machines from serial number 062211247] . ........................... 50 STEERING COLUMN TILTING ADJUSTING LEVER REPLACEMENT [for machines from serial number 062211247] ..................................................................................................... 52 ELECTRICAL SYSTEM ............................................................................................................................................ 53 BATTERY CHARGE AND MAINTENANCE ......................................................................................................... 53 BATTERY INSTALLATION AND BATTERY TYPE SETTING (WET OR GEL) . .................................................. 53 DRIVE SYSTEM ELECTRONIC BOARD REPLACEMENT . ............................................................................... 54 HOUR COUNTER AND BATTERY VOLTAGE DISPLAY ELECTRONIC BOARD REPLACEMENT ................... 55 NON-START FUNCTION CHECK (WITHOUT OPERATOR ON THE DRIVER’S SEAT) .................................... 55 HOOD SAFETY SWITCH OPERATION CHECK ................................................................................................. 55 NON-START FUNCTION CHECK (WITH BATTERY CHARGER CONNECTED TO THE ELECTRICAL MAINS) . ......................................................................................................................... 55 COMPONENT LAYOUT ....................................................................................................................................... 56 WIRING DIAGRAM .............................................................................................................................................. 59

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GENERAL INFORMATION MACHINE LIFTING WARNING! Do not work under the lifted machine without supporting it with safety stands.

MACHINE TRANSPORTATION WARNING! Before transporting the machine, make sure that: – All lids and cases are closed.

– 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 instructions in the User Manual. Failure to follow these instructions may cause damage to the machine.

OTHER REFERENCE MANUALS AVAILABLE FOR TERRATM 4300B The following manuals are available at Nilfisk Literature Service Department: – TerraTM 3700B - User Manual – Nilfisk Form Number 146 1963 000 – TerraTM 3700B - Spare Parts List – Nilfisk Form Number 146 1964 000 – TerraTM 3700B - Battery Charger Kit – Nilfisk Form Number 146 2055 000 – TerraTM 3700B - Manual Vacuum System Kit – Nilfisk Form Number 146 2049 000 – TerraTM 3700B - Working light Kit – Nilfisk Form Number 146 2053 000 – TerraTM 3700B - Pivoting Light Kit – Nilfisk Form Number 146 2054 000 – TerraTM 3700B - Buzzer Kit – Nilfisk Form Number 146 2128 000

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 remark related to important or useful functions.

Pay careful attention to the paragraphs marked by this symbol.

NOTE It indicates a caution or a remark related to important or useful functions.

CONSULTATION It indicates the necessity to refer to the User Manual before performing any procedure.

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GENERAL INFORMATION GENERAL SAFETY PRECAUTIONS Specific warnings and cautions to inform about potential damages to people and machine are shown below.

DANGER! – – – – – – –

Remove the ignition key and disconnect the batteries before performing any maintenance/repair procedure.

This machine must be used by properly trained and authorised personnel only. Children or disabled people cannot use this machine.

Keep the battery away from sparks, flames and incandescent material. During the normal operation explosive gases are released.

Do not wear jewels when working near electrical components.

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

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

Battery charging produces highly explosive hydrogen gas. Keep the hood open during battery charging and perform this procedure in well-ventilated areas and away from naked flames.

WARNING!

– – – – – – – – – – – – – – – – – – – – – –

Carefully read all the instructions before carrying out 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 while charging the batteries.

Do not leave the machine unattended while the ignition key is inserted without being sure that the machine cannot move independently.

Do not use the machine on slopes with a gradient exceeding the specifications.

Do not wash the machine with direct or pressurised water jets, or with corrosive substances. Do not use compressed air to clean this type of machine.

Do not use the machine in particularly dusty areas.

While using this machine, take care not to cause damage to people and property.

The machine storage temperature must be between +32°F and +104°F (0°C and +40°C).

The machine working temperature must be between +32°F and +104°F (0°C and +40°C).

The humidity must be between 30% and 95%.

Always protect the machine against the sun, rain and bad weather, both under operation and inactivity condition.

Do not use the machine as a means of transport.

Do not allow the brooms to operate while the machine is stationary to avoid damaging the floor.

In case of fire, possibly use a powder fire extinguisher, not a water one.

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

If parts must be replaced, require ORIGINAL spare parts from a Dealer or Authorised Retailer.

The machine must be disposed of properly, because of the presence of toxic-harmful materials (batteries, oils, etc.), which are subject to standards that require disposal in special centres (see Scrapping chapter in the User Manual).

Be very careful when operating the machine at high speed: sudden steering could cause this three-wheel machine to become unstable due to weight distribution.

Always reduce the speed before steering.

If the machine is used according to the instructions, the vibrations are not dangerous. The machine vibration level is less than 2.5 m/s2 (98/37/EEC-EN-1033/1995-EN 1032).

When lead (WET) batteries are installed, do not tilt the machine for more than 30° from the horizontal plane to prevent the highly corrosive acid from leaking out of the batteries. When the machine is to be tilted to perform maintenance procedures, remove the batteries.

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GENERAL INFORMATION TECHNICAL DATA Dimensions

Values

Minimum machine length

49.4 in (1,255 mm)

Machine width (without side brooms)

31.3 in (795 mm)

Maximum machine height (steering wheel with knob)

45.47 in (1,155 mm)

Working width (with/without side brooms)

39.4/23.6 in (1,000/600 mm)

Minimum distance from the ground (skirts not included)

1.6 in (40 mm)

Main broom size

10.43 x 23.62 in (265 mm x 600 mm)

Side broom size

16.53 in (420 mm)

Front driving and steering wheel size

7.87 x 1.97 in (200 x 50 mm)

Rear wheels

9.84 x 1.97 in (250 x 50 mm)

Machine total weight

317.5 lb (144 kg) (without batteries)

Forward speed

5.5 km/h

Reverse speed

4.4 km/h

Gradeability

16%

Hopper capacity

9.5 gal (36 litres)

Main broom and vacuum fan motor

600 W

Side broom motors

60 W

Drive system motor

400 W

Filter shaker motor

12 W

Sound pressure level at workstation (LpA)

71.6 dB(A)

Batteries

Values

Battery voltage

24 V

Standard batteries

Lead (WET), with acid electrolyte

Optional battery

Gel (GEL), hermetic

Battery capacity

100 – 240 Ah C5

Battery compartment maximum size

14.1x14.8x15.2 in (357x375x385 mm)

Dust vacuuming and filtering

Values

Paper dust filter 5-10 µm

32.3 ft2 (3 m2)

Main broom compartment vacuum

0.75 inH2O (18 mmH2O)

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GENERAL INFORMATION MAINTENANCE

The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance.

WARNING! See GENERAL INFORMATION and SAFETY - ACCIDENT PREVENTION 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.

For maintenance procedures, see the following paragraphs.

SCHEDULED MAINTENANCE TABLE Maintenance operation

Upon delivery

Every 10 hours

Every 50 hours

Every 100 hours

Battery fluid level check Side and main broom height check and adjustment Dust filter cleaning and integrity check Skirt height and operation check Filter shaker operation check Hood safety switch operation check Main broom driving belt check Nut and screw tightening check

(1)

Service and parking brake check and adjustment Main broom driving belt replacement Main motor and drive system motor carbon brush check and replacement

(1): And after the first 8 running-in hours.

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Every 200 hours

Every 400 hours

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GENERAL INFORMATION MACHINE NOMENCLATURE Throughout this Manual you will find numbers in brackets – for example: (2). These numbers refer to the components shown in these two nomenclature pages. Refer to these pages whenever it is necessary to identify a component mentioned in the text..

1.

2.

3.

4.

5.

6.

7.

Left control panel Ignition key Discharged battery warning light Semi-discharged battery warning light Charged battery warning light Display Display selection button: hour counter/hour and minute counter/battery voltage (V) 9. Horn switch 10. Switch having the following functions: • in the central position: off • pushed forward (fixed): it turns on the main broom and the vacuum fan • pushed backward (not fixed): it turns on the filter shaker 12. Manual vacuum system switch (optional) 13. Working light switch (optional) 14. Emergency push-button 15. Control panel mounting screws 16. Right control panel 17. Steering wheel 18. Steering column tilting adjusting lever 19. Vacuum activation/deactivation lever 20. Side broom lifting/lowering lever 21. Forward/reverse gear pedal 22. Service brake pedal 23. Parking brake lever (it acts on the front wheel) 23a. Brake engaged 23b. Brake disengaged 24. Front skirt lifting pedal 25. Can holder 26. Hood 27. Rear wheels on fixed axle 28. Front driving and steering wheel 29. Right side broom 30. Left side broom 31. Main broom 32. Left side skirt 33. Right side skirt 34. Front skirt 35. Rear skirt 36. Hopper 37. Hopper hook 38. Hopper handle 39. Main broom left lid 40. Main broom height left adjuster 41. Main broom height right adjuster 42. Main broom right lid 43. Main broom right lid mounting screws 44. Pivoting light (always on when the ignition switch is turned to “I” position) (optional) 45. Driver’s seat with safety microswitch 46. Additional hole for manual vacuum system kit (optional) 47. Adjustable steering column 48. Working light (optional) 49. Side broom height adjusting knob 50. Seat longitudinal position adjusting lever 51. Manual vacuum system (optional) 56. Serial number plate/technical data/EC certification 59. Hood (open) 60. Hood support rod

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

76.

77.

78.

Batteries Battery caps (for WET batteries) Battery connector Electronic battery charger (optional) Battery charger cable Lamellar fuse box (accessories) Drive system circuit breaker Main broom/vacuum fan motor circuit breaker Lead (WET) or gel (GEL) battery selector on the optional electronic battery charger Charged battery warning light Main broom belt Main broom drive pulley Vacuum fan Main motor Manual vacuum system (optional) Switch for machine pushing Battery installation diagrams

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GENERAL INFORMATION MACHINE NOMENCLATURE (for machines up to serial number 062211246)

1

14

16

3

4

5

2 10 12 13 15

7

6

45

50

26

23

22

48

51 17

31 46

24 29

9

40

28 30

34

39 32

27

44

18 20

19 47

49

25 21

37 43

22 23b

38 23a 36 27 35

42

33

41

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GENERAL INFORMATION MACHINE NOMENCLATURE (for machines up to serial number 062211246)

63

6V 6V

64

6V 6V 59

78

63 61

93

12V

64

12V

67 66

68 77

60 56 63 61 62

76 64 73

70 65

74 72 71 92

69

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GENERAL INFORMATION MACHINE NOMENCLATURE (for machines from serial number 062211247)

18

1

14

16

3 4

5

2 10 12

13

7

15

6

9

26

45

51

50

17 22

31 24

29

48

46

40

28 30

34

32

39

27

44

23 23b 23a 20 49

19 96 47 25 21

37 43 38

36 27 35

42

33

41

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GENERAL INFORMATION MACHINE NOMENCLATURE (for machines from serial number 062211247)

63

59

78

6V

6V

6V

6V

63

64

61 64

12V

93 12V

60

67 66

68 77

56 63 61

62 76 64 73

70 65

74 72 71 92

69

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SWEEPING SYSTEM MOTOR-TO-MAIN BROOM BELT CHECK 1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Check the condition of the belt (71) between the motor and the main broom. To check the belt, turn it by manually operating on the fan (73).

If the belt is worn, replace it.

Check that the belt tensioner (92) is in good condition.

Disengage the support rod (60) and close the hood (26).

MOTOR-TO-MAIN BROOM BELT REPLACEMENT 1.

2.

3.

4.

5.

6.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0”.

Remove the main broom.

Remove the belt (71) from the pulley (72); for an easier removal, turn the pulley (72) by manually operating on the fan (73).

Remove the screws (43) and the right lid (42) together with the belt (71).

Install the components in the reverse order of removal.

Install the tensioner (92) of the belt (71) as shown in the figure.

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SWEEPING SYSTEM MAIN BROOM HEIGHT CHECK AND ADJUSTMENT NOTE Brooms with harder or softer bristles are available. This procedure is applicable to all types of brooms.

Check 1.

Check that the main broom is at the correct distance from the ground, according to the following procedure: • Drive the machine on a level ground.

• Keep the machine stationary and turn on the main broom for a few seconds.

• Stop the main broom, then move the machine and turn it off.

• Check that the main broom print (A), along its length, is 0.8-1.2 in (2-4 cm) wide.

If the print (A) is not within specifications, adjust the broom height according to the following procedure.

CAUTION! If the main broom print is excessive (larger than 1.57 in (4 cm)), the machine regular operation is affected and the moving or electrical parts can overheat, thus reducing machine life.

Pay careful attention when performing the above-mentioned checks, and always use the machine according to the indicated conditions.

Adjustment 1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0”.

Loosen the knobs (B) on both sides of the machine.

On both sides of the machine, unscrew the knobs (B) and move the broom height variation indicator (C) as necessary, then screw down the knobs (B).

The indicator (C) must be in the same position on both sides of the machine; the maximum difference allowed to obtain the print (A) shown in step 1 (0.78 – 1.57 in (2 - 4 cm) wide) is two notches.

Perform step 1 again to check that the main broom is at the correct distance from the ground.

When the broom is too worn and can no longer be adjusted, replace it according to the procedure shown in the following paragraph.

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SWEEPING SYSTEM MAIN BROOM REPLACEMENT NOTE Brooms with harder or softer bristles are available. This procedure is applicable to all types of brooms.

CAUTION! It is advisable to wear protective gloves when replacing the main broom because there can be sharp debris between the bristles.

1.

2.

3.

4.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Loosen the knobs (A) on both sides of the machine.

Move the height variation indicators (B) until the broom is at the maximum distance from the ground. Screw down the knobs (A).

5. On the left side of the machine, loosen the knob (C).

6. Remove the broom lid (D) by pulling it upwards to disengage the fasteners (E).

7. Remove the broom (F).

8. Install the new broom with the bristles rows (G) bent as shown in the figure (top view).

9. Install the new broom on the machine and ensure that its mesh (H) correctly fits into the relevant drive hub (I).

Check that the drive hub (I) is free from dirt or foreign materials (cords, rags, etc.) accidentally rolled up.

10. Install the broom lid (D) by engaging the fasteners (E).

11. Screw down the knob (C).

12. Adjust the new broom height according to the procedure shown in the previous paragraph.

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I

G

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SWEEPING SYSTEM SIDE BROOM HEIGHT CHECK AND ADJUSTMENT NOTE Brooms with harder or softer bristles are available. This procedure is applicable to all types of brooms.

Check 1.

Check the side broom distance from the ground, according to the following procedure: • Drive the machine on a level ground and lower the side brooms.

• Keep the machine stationary and turn on the side brooms for a few seconds.

• Lift the side brooms, then move the machine.

• Check that the size and orientation of the prints left by the side brooms (A) are as follows. If the print is not within specifications, it is necessary to adjust the broom height, according to the procedure shown in step 2.

Height adjustment for both side brooms 2.

Disengage the lever (20) and turn the knob (49) clockwise or counterclockwise to adjust the side broom height.

Perform step 1 again to check the proper adjustment of the side broom height.

When the brooms are too worn and can no longer be adjusted, replace them according to the procedure shown in the relevant paragraph.

If the brooms have to be adjusted individually, perform the following procedure.

Height adjustment for one side broom 3.

4.

5.

6.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

7.

8.

9.

Paying careful attention and with the help of an assistant, lift the machine front side (C), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (D).

Operating on the control cable (E) of the broom which needs to be adjusted, loosen the locknut (F) and tighten/loosen the screw (G) as necessary; then tighten the locknut (F).

When the brooms are too worn and can no longer be adjusted, replace them according to the procedure shown in the relevant paragraph.

Perform steps 3 to 8 in the reverse order.

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SWEEPING SYSTEM SIDE BROOM HEIGHT CHECK AND ADJUSTMENT (continues)

B

A

C

D

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SWEEPING SYSTEM SIDE BROOM REPLACEMENT NOTE Brooms with harder or softer bristles are available. This procedure is applicable to all types of brooms.

CAUTION! It is advisable to wear protective gloves when replacing the side brooms because there can be sharp debris between the bristles.

1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Operating inside the side broom, loosen the screw (A) and then remove the broom with the hub (B) by disengaging it from the shaft (C). Recover the key (D) and the washer (E).

At the workbench, remove the two screws (F) and separate the broom (H) from the hub (G).

Install the new broom (H) onto the hub (G), and tighten the screws (F).

Fit the key (D) and install the broom with the hub (B). Install the washer (E) and tighten the screw (A).

Adjust the side broom height, as described in the previous paragraph.

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SWEEPING SYSTEM MAIN MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only.

Preliminary operations 1.

2.

3.

4.

5.

Check and adjust the main broom.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Connect the main motor (74) to the battery (61) as shown in the diagram (A), by inserting the 30 A fuse (B) to protect the system.

Apply an ammeter (C) to the connection (A) and route the connection so that the hood (26) can be closed; then perform the test shown in the next step. In this way, the ammeter (C) can be seen by the operator seated on the machine.

Check the main motor electrical input 6.

Start the machine and perform a sweeping simulation, according to the procedures shown in the User Manual. The following conditions are required: • Lower the main broom.

• Lift the side brooms.

• Drive the machine at the maximum speed.

• Clean the vacuum filter by using the filter shaker.

• Drive the machine on a stretch of level ground, in both directions, while recording both values.

• Do not let the engine overheat.

In these conditions, record the main motor electrical input by using the ammeter (C).

Stop the machine and compare the readings with the values listed in the table below, according to the kind of ground the test has been performed on.

Kind of ground Smooth concrete base Light carpet Heavy carpet

A 20 - 22 20 - 22 26

If the electrical input is higher, perform the following procedures to detect the cause and correct the abnormal input: • Remove dirt or foreign materials from the main broom drive system, which can clog or slow down its normal movement.

• If necessary, check the motor carbon brushes.

• If necessary, remove, clean and check the main motor.

If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced.

Reset 7.

Perform steps 4 and 5 in the reverse order.

C 30A A

B

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SWEEPING SYSTEM STARTER/DYNAMO OR MAIN MOTOR CARBON BRUSH CHECK AND REPLACEMENT 1.

2.

3.

4.

5.

6.

7.

8.

9.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Disconnect the battery connector (63).

Clean the outer part of the motor, then disengage and remove the band (A).

Lift the retaining springs (B) and remove the four carbon brushes (C).

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufficient, the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc.

If necessary, remove the carbon brushes to replace them, by removing the nuts (D) and disengaging the lead-in wires (E).

Replace the carbon brushes as an assembly.

Install the components in the reverse order of removal, and note the following: When connecting the terminals (E), take care of their insulation from the surrounding parts of the frame.

C

C

D B

E

E

A C

E C

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SERVICE MANUAL

SWEEPING SYSTEM MAIN MOTOR AND REDUCTION UNIT REMOVAL / INSTALLATION Removal 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Disconnect the battery connector (63).

Remove the belt (71) from the pulley (72); for an easier removal, turn the pulley (72) by manually operating on the fan (73).

Remove the four screws (A) and carefully lift the panel (B).

Disconnect the negative “black” cable (C) of the main motor (D) from the contact (E).

Remove the two screws (F) and carefully move the panel (G).

Disconnect the positive “red” cable (H) of the main motor (D) from the fusible link (I).

Remove the cable (L) of the main motor (D) from the machine frame.

Remove the three screws (M) and the nut (N), then remove the motor/reduction unit (O) and the manual vacuum system (P), if equipped.

Disassembly at the workbench 12. At the workbench, remove the screw (Q) and disconnect the connector (R), then remove the manual vacuum system (P), if equipped.

13. Remove the nuts (S).

14. Remove the screws (T) and the reduction unit (U) by disengaging it from the motor (V). Recover the key (W).

15. Remove the screw (X), then remove the fan (Y).

16. Remove the screws (Z), then remove the main motor (V).

Installation 17. Install the components in the reverse order of removal.

Install the motor/reduction unit (O) with the three screws (M) and the nut (N), use the slots (AC) in order to place the unit (O) and the fan (AA) as close as possible to the machine cover (AB) without touching it.

A B L

G

F F

AB AA D

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SWEEPING SYSTEM MAIN MOTOR AND REDUCTION UNIT REMOVAL / INSTALLATION (continues)

U V W Y

W

X

Z

T

Z T S

M

S

M

AC

S S M

AA O

R AC

AC P

Q

N Q

Q

Q S300814

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SERVICE MANUAL

SWEEPING SYSTEM STARTER/DYNAMO AND REDUCTION UNIT REMOVAL/INSTALLATION Removal 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Disconnect the battery (61) negative pole.

Remove the belt (71) from the pulley (72); for an easier removal, turn the pulley (72) by manually operating on the fan (73).

Remove the screws (AD), then move the bracket (AE).

Remove the four screws (A) and carefully lift the panel (B).

Disconnect the negative “black” cable (C) of the starter/dynamo (D) from the contact (E).

Disconnect the positive “red” cable (H) of the starter/dynamo (D) from the ES1 electromagnetic switch (I).

Remove the three screws (F) and carefully move the panel (G).

Remove the cable (L) of the starter/dynamo (D) from the machine frame.

Remove the screw (AM) and carefully move the baffle plate (AN).

Remove the belt (89) from the pulley (94); for an easier removal, turn the pulley (94) by manually operating on the fan (73).

Remove the three screws (M) and the nut (N), then remove the starter/dynamo (O) and the manual vacuum system (P), if equipped.

Disassembly at the workbench 15. At the workbench, remove the screw (Q) and disconnect the connector (R), then remove the manual vacuum system (P), if equipped.

16. Remove the nuts (S).

17. Remove the screw (X) and the threaded dowel (AO), then remove the fan (Y) and recover the key (AF).

18. Remove the threaded dowel (AL), the pulley (AI), the adapter (AG) and recover the key (AH).

19. Remove the screws (Z), then remove the reduction unit (U) and the starter/dynamo (V).

20. Remove the screws (T), then remove the reduction unit (U) by disengaging it from the starter/dynamo (V). Recover the key (W).

Installation 21. Install the components in the reverse order of removal.

Install the starter/dynamo and reduction unit (O) with the three screws (M) and the nut (N), use the slots (AC) in order to place the unit (O) and the fan (AA) as close as possible to the machine cover (AB) without touching it.

AN

A B

G

L

AM

F F

AB AA D S300815

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SWEEPING SYSTEM STARTER/DYNAMO AND REDUCTION UNIT REMOVAL/INSTALLATION (continues)

U

V

W

W

T

Z

AG

X

AO

Y

AF

AH AL Z AI

T N

M

S AC

S

S

M AA O AE R

AC

P

Q AD

Q

N

Q

Q S300816

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SERVICE MANUAL

SWEEPING SYSTEM SIDE BROOM MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only.

Preliminary operations 1.

2.

3.

4.

5.

Check and adjust the side brooms.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Connect the right (29) or left (30) broom motor to the battery (61) as shown in the diagram (A), by inserting the 5 A fuse (B) to protect the system.

Apply an ammeter (C) to the connection (A) and route the connection so that the hood (26) can be closed; then perform the test shown in the next step. In this way, the ammeter (C) can be seen by the operator seated on the machine.

Side broom motor electrical input check 6.

Start the machine and perform a sweeping simulation, according to the procedures shown in the User Manual. The following conditions are required: • Lift the main broom.

• Lower the side brooms.

• Drive the machine at the maximum speed.

• Clean the vacuum filter by using the filter shaker.

• Drive the machine on a stretch of level ground, in both directions, while recording both values.

• Do not let the engine overheat.

In these conditions, record the side broom motor electrical input by using the ammeter (C).

Stop the machine and compare the readings with the values listed in the table below, according to the kind of ground the test has been performed on.

Kind of ground Smooth concrete base Asphalt Light carpet Heavy carpet

A 2.1 2.6 2.7 2.8

If the electrical input is higher, perform the following procedures to detect the cause and correct the abnormal input: • Remove dirt or foreign materials from the side broom drive system, which can clog or slow down its normal movement.

• If necessary, remove, clean and check the side broom motors.

If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced.

Reset 7.

Perform steps 4 and 5 in the reverse order.

C 5A A

B

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SWEEPING SYSTEM SIDE BROOM MOTOR REMOVAL/INSTALLATION 1.

2.

3.

4.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

5.

Paying careful attention and with the help of an assistant, lift the machine front side (I), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (A).

6. Remove the side broom (B).

7. Remove the screw (C).

8. Remove the hub (D) and take out the key (D).

9. Disconnect the connector (F).

10. Remove the screws (G).

11. Remove the side broom motor (H).

12. Install the components in the reverse order of removal.

H I

F

E

G D

A

C

B

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SERVICE MANUAL

SWEEPING SYSTEM SIDE BROOM LIFTING CABLE REPLACEMENT [for machines from serial number 062211247] Disassembly 1.

2.

3.

Remove the front cover (see the procedure in the relevant paragraph).

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

4.

Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

Disconnect the terminals (C) of the side broom lifting cables (D) from the fasteners (E) of the lifting lever (F).

Unscrew the adjusters (G).

Remove the clips (H) and disconnect the terminals (I).

Unscrew the adjusters (J).

Disengage the side broom lifting cables (D) from the relevant housings, then remove them.

5.

6.

7.

8.

9.

Assembly 10. Assemble the components in the reverse order of disassembly.

11. Adjust the side broom height (see the procedure in the relevant paragraph).

A

E E

B

F

C D

D

G J

J

I

C

H

I

G

H

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SWEEPING SYSTEM SIDE BROOM MICROSWITCH ADJUSTMENT/REPLACEMENT [for machines from serial number 062211247] Check 1.

2.

Start the machine as shown in the User Manual.

Turn on the side brooms then lift them with the lever (20) and check that the brooms turn off before the lever reaches the upper end-of-stroke.

Otherwise, adjust the microswitch according to the following procedure.

Adjustment/replacement 3.

4.

5.

6.

Remove the front cover (see the procedure in the relevant paragraph).

Loosen the mounting screws (A) of the microswitch (B).

By using the slot (C), adjust the position of the microswitch (B) and the relevant tab (D) activated by the lever (E), until the condition shown in step 2 is satisfied (instead of broom stop, the “tic” sound (microswitch activation) must be heard).

If necessary, disconnect the connections (F), remove the screws (A) and replace the microswitch (B). After installing the microswitch (B), adjust it as shown in step 5.

Reset 7.

8.

Install the front cover (see the procedure in the relevant paragraph).

Perform step 2 again.

B

F

D E C

A

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SERVICE MANUAL

SWEEPING SYSTEM TROUBLESHOOTING THE MACHINE DOES NOT START When turning the ignition key (2) to “I” the control panel does not turn on.

Possible causes: 1. The battery connector (63) is not properly connected (connect).

2. The hood (26) is not properly closed (close).

3. The battery is discharged (charge the battery).

4. One of the cables under the control panel (1) or (16) may be disconnected (check).

THE CONTROL PANEL TURNS ON BUT THE MOTORS DO NOT START Possible causes: 1. The electromagnetic switch is faulty (replace).

THE MAIN BROOM DOES NOT TURN Possible causes: 1. There are dust or foreign materials preventing the operation of the main broom drive system (remove).

2. The main motor carbon brushes are worn (replace).

3. The main motor is faulty (repair or replace).

4. The main motor driving belt is broken (replace).

5. The wiring harness is damaged (repair).

6. There is an open in the fuse (68) (reset).

THE SIDE BROOMS DO NOT TURN Possible causes: 1. There are dust or foreign materials between the broom and the motor (remove them).

2. The motor is faulty (repair or replace).

3. The F6 fuse is blown (replace).

4. The wiring harness is damaged (repair).

5. The broom microswitch is misadjusted or damaged (adjust or replace).

THE MOTORS KEEP RUNNING EVEN IF THE IGNITION KEY IS TURNED TO “0” Possible causes: The electromagnetic switch is faulty (replace).

WARNING! In this case, pay careful attention when disconnecting the battery connector (63), because the hood safety system is not operating.

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SKIRT SKIRT HEIGHT AND OPERATION CHECK 1.

2.

3.

Drive the machine on a level ground that is suitable for checking the skirt height.

Engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Side skirt check 4.

4.

Check the side skirts (32 and 33) for integrity.

Replace the skirts when they have cuts (A) larger than 0.078 in (20 mm) or cracks (B) larger than 0.039 in (10 mm) (for skirt replacement, see the relevant paragraph).

Check that the distance from the ground of the side skirts (C) is 0 to 0.12 in (0 to 3 mm) (as shown in the figure). If necessary, adjust the skirt height according to the following procedure: Left skirt: • Open the hood (26) and engage the hood support rod (60).

• Loosen the knob (D) and remove the broom left lid (E) by pulling it upwards to disengage the fasteners (F).

• Adjust the height of the skirt (G) by using the slots (H).

• Install the components in the reverse order of removal.

Right skirt: • Remove the main broom, as shown in the relevant paragraph.

• Remove the belt (71) from the pulley (72); for an easier removal, turn the pulley (72) by manually operating on the fan (73).

• Remove the screws (43) and the right lid (42) together with the belt (71).

• Adjust the height of the skirt (I) by using the slots (L).

• Install the components in the reverse order of removal.

Front and rear skirt check 6.

7.

8.

Remove the main broom, as shown in the relevant paragraph.

Check the front (M) and rear (N) skirts for integrity.

Replace the skirts when they have cuts (A) larger than 0.078 in (20 mm) or cracks (B) larger than 0.039 in (10 mm) (for skirt replacement, see the relevant paragraph).

9. Check that: • The front skirt (O) slightly touches the ground and is not detached from the ground (as shown in the figure).

• The distance from the ground of the rear skirt (C) is 0 to 0.12 (0 to 3 mm) (as shown in the figure).

If necessary, adjust the skirt height by using the slots (P).

10. Press the front skirt lifting pedal (24) and check that the front skirt (Q) turns upward for about 90° (as shown in the figure); release the pedal and check that the skirt does not remain in an intermediate position but returns to its initial position. If necessary, for the front skirt control cable adjustment or replacement, see the following pages.

11. Install the components in the reverse order of removal.

S300246

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SERVICE MANUAL

SKIRT SKIRT HEIGHT AND OPERATION CHECK (continues)

S300248

S300249

M

30

146 1965 000(2)2007-02

P

P

N

S300250

S300251

S300376

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ENGLISH

SKIRT SIDE SKIRT REPLACEMENT 1.

2.

3.

Drive the machine on a level ground that is suitable for checking the skirt height.

Engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Left skirt 4.

5.

6.

7.

8.

Loosen the knob (A) and remove the broom left lid (B) by pulling it upwards to disengage the fasteners (C).

Remove the screws (D), the strap (E) and the side skirt (F).

Install the new skirt (F) with the strap (E) and the screws (D).

Adjust the side skirt height as shown in the previous paragraph.

Install the components in the reverse order of removal.

Right skirt 9.

10.

11.

12.

13.

14.

15.

Remove the main broom, as shown in the relevant paragraph.

Remove the belt (71) from the pulley (72); for an easier removal, turn the pulley (72) by manually operating on the fan (73).

Remove the screws (43) and the right lid (42) together with the belt (71).

Remove the screws (G), the strap (H) and the side skirt (I).

Install the new skirt (I) with the straps (H) and the screws (G).

Adjust the side skirt height as shown in the previous paragraph.

Install the components in the reverse order of removal.

S300253

S300254

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SERVICE MANUAL

SKIRT FRONT AND REAR SKIRT REPLACEMENT 1.

2.

3.

4.

5.

Drive the machine on a level ground that is suitable for checking the skirt height.

Engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the main broom, as shown in the relevant paragraph.

Slightly lift the machine front side observing the cautions below, then remove the clip (E) and disconnect the lifting cable terminal (F) from the front skirt (G).

CAUTION! When lead (WET) batteries are installed, do not tilt the machine for more than 30° from the horizontal plane to prevent the highly corrosive acid from leaking out of the batteries.

6.

7.

8.

9.

10.

Remove the front skirt (A) and/or the rear skirt (B) by loosening the screws (C) and by removing the strap (D).

Install the new skirt (A) and/or (B) with the strap (D) and the screws (C).

Adjust the skirt height according to the procedure shown in the relevant paragraph.

Install the components in the reverse order of removal.

If necessary, for the front skirt control cable adjustment, see the relevant paragraph.

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ENGLISH

SKIRT FRONT SKIRT LIFTING CABLE ADJUSTMENT Adjustment check 1.

2.

3.

4.

5.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the main broom, as shown in the relevant paragraph.

Press the front skirt lifting pedal (24) and check that the front skirt (A) turns upward for about 90° (as shown in the figure); release the pedal and check that the skirt does not remain in an intermediate position but returns to its initial position.

If necessary, adjust the front skirt lifting cable as shown below.

Cable adjustment 6.

7.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

CAUTION! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

8.

Paying careful attention and with the help of an assistant, lift the machine front side (F), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

9. In order to adjust the front skirt lifting cable (E), loosen the lock nut (C) and turn the terminal (D) as necessary. Tighten the locknut (C).

10. Perform step 4 again to check adjustment.

11. Install the components in the reverse order of removal.

S300820

F

B

S300821

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SERVICE MANUAL

SKIRT FRONT SKIRT LIFTING CABLE REPLACEMENT 1.

2.

3.

4.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

CAUTION! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

5.

Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

6. Loosen the locknut (I), then remove the cable terminal (J).

7. Remove the clip (C) and disconnect the lifting cable terminal (D) from the front skirt (E).

8. Remove the clip (F) and disconnect the lifting cable terminal (G) from the pedal (H).

9. Remove the front skirt lifting cable (K).

10. Install the components in the reverse order of removal.

11. Adjust the front skirt lifting cable (see the procedure in the previous paragraph).

A

H

K J F

B

G I

C

D

E S300822

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DUST AND DEBRIS COLLECTION SYSTEM DUST FILTER CLEANING AND INTEGRITY CHECK NOTE Besides the standard paper filter, polyester filters are also available. The following procedure is applicable to each type of filter.

1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper hook (37).

Remove the hopper (36) with the handle (38).

Turn the handle (A) downwards (90° approximately) and let the filter frame (B) turn outwards.

Remove the dust filter (C).

In an appropriate outdoor area, clean the filter by shaking it on a level and clean surface, tapping the side (D) opposite to the wire gauze (E). Complete the cleaning procedure by using compressed air (F) at maximum 87 psi (6 Bar), blowing only from the side protected by the wire gauze (E), at a minimum distance of 12 in (30 cm) (see the figure).

Moreover, according to the filter type, observe the following cautions: • Paper filter (standard): Do not use water or detergents to clean it, otherwise it can be damaged.

• Polyester filter (optional): To clean it, see the above-mentioned instructions. If necessary, for a better cleaning, it is allowed to wash the filter with water and non-lathering detergents. This provides better quality cleaning but reduces the life of the filter, which will have to be replaced more frequently. The use of inadequate detergents can damage the filter.

8. Check the filter body for tears.

9. If necessary, clean the filter compartment rubber seal (G) along its perimeter and check it for integrity. If necessary, replace it.

10. Install the components in the reverse order of removal.

11. Install the filter with the gauze (E) facing the fan (73).

C

B G

A

S300823

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SERVICE MANUAL

DUST AND DEBRIS COLLECTION SYSTEM FILTER SHAKER OPERATION CHECK 1.

2.

3.

When the panel filter is clogged, turn on the filter shaker by pressing the relevant push-button (10) for a few seconds, and check for the typical noise.

Restart the machine and check that the filter has been properly shaken. If so, this should result in an appreciable improvement in the machine vacuum capability.

If necessary, check and replace the filter shaker (see the procedure in the relevant paragraph).

FILTER SHAKER MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only.

1.

2.

3.

4.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0”.

Remove the hopper (36) as shown in the User Manual.

Check the brooms are lifted.

WARNING! Pay careful attention when performing the following procedures.

5.

6.

Turn the ignition key (2) to “I” and do not press the drive pedal (21).

Turn on the filter shaker by pressing the relevant push-button (10) and apply an ammeter (A) on the cable (B). Check that the electrical input of the filter shaker motor (C) is 3 - 5 A at 24 V. Turn the ignition key (2) to “0”. Remove the ammeter.

If the electrical input is higher, the motor must be replaced.

Install the hopper (36) as shown in the User Manual.

7.

S300259

TROUBLESHOOTING THE FAN DOES NOT TURN Possible causes: 1. The batteries are discharged (charge).

2. The main motor carbon brushes are worn (replace).

3. The main motor is faulty (repair or replace).

4. There are foreign materials clogging the fan (remove).

5. The wiring harness is damaged (repair).

THE FILTER SHAKER MOTOR DOES NOT OPERATE Possible causes: 1. The motor is faulty (repair or replace).

2. The filter shaker push-button (10) is damaged (replace).

3. The filter shaker is faulty (replace).

4. The wiring harness is damaged (repair).

5. The filter shaker motor fuse is blown (replace).

6. There is dust in the filter shaker motor vibrating mass case (remove and clean).

7. The filter shaker motor temperature is excessive (let it cool down and try again).

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MANUAL VACUUM SYSTEM MANUAL VACUUM SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT 1.

2.

3.

4.

5.

6.

7.

8.

Remove the manual vacuum system motor.

At the workbench, remove the guard (A) by disengaging the inner fasteners.

Disconnect the carbon brush connections (B).

Remove the carbon brush mounting screws (C).

Remove the carbon brushes (D).

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufficient, the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc.

If necessary, replace the carbon brushes. Replace the carbon brushes as an assembly.

Install the components in the reverse order of removal.

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SERVICE MANUAL

MANUAL VACUUM SYSTEM MANUAL VACUUM SYSTEM MOTOR REMOVAL/INSTALLATION 1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Remove the nuts (A), then remove the screws with washers (B).

Remove the manual vacuum system motor connection (C).

Remove the manual vacuum system motor (D) and recover the key (E).

Install the components in the reverse order of removal.

B B

B D

C

E

A

S301197

TROUBLESHOOTING POOR VACUUMING PERFORMANCE OF THE MANUAL VACUUM SYSTEM Possible causes: There are dust or foreign materials slowing down the operation of the manual vacuum system (remove).

The motor carbon brushes are worn (replace).

The motor is faulty (repair or replace).

THE MANUAL VACUUM SYSTEM DOES NOT START Possible causes: 1. There are dust or foreign materials preventing the operation of the manual vacuum system (remove).

2. The motor carbon brushes are worn (replace).

3. The motor is faulty (repair or replace).

4. The fuse is blown (replace).

5. The manual vacuum system switch is damaged (replace).

6. The wiring harness is damaged (repair).

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ENGLISH

BRAKE SYSTEM BRAKE ADJUSTMENT [for machines up to serial number 062211246] Check 1.

Engage the parking brake with the lever (23a) and check the brake performance.

NOTE Brakes and parking brake adjustment must be performed while engaging the parking brake as shown above.

The brake travel will be adjusted accordingly.

2.

If necessary, adjust the brakes according to the following procedure.

Adjustment 3.

4.

5.

6.

Drive the machine on a level ground without engaging the parking brake (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

7.

Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

8. Remove the clip (C) from the brake tie rod.

9. Remove the fork (D) from the brake lever (E).

10. Loosen the locknut (F) or (G) and loosen/tighten the threaded tie rod (H) on the fork (D) or (I) as necessary. Then tighten the locknut (F) or (G).

11. Perform steps 4 to 9 in the reverse order.

12. Perform hands-on tests to check parking brake and brake operation.

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ENGLISH

SERVICE MANUAL

BRAKE SYSTEM BRAKE ADJUSTMENT [for machines up to serial number 062211246] (continues)

A

B

S300826

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ENGLISH

BRAKE SYSTEM BRAKE ADJUSTMENT [for machines from serial number 062211247] Check 1.

Engage the parking brake with the lever (23a) and check the brake performance.

NOTE Brakes and parking brake adjustment must be performed while engaging the parking brake as shown above.

The brake travel will be adjusted accordingly.

2.

If necessary, adjust the brakes according to the following procedure.

Adjustment 3.

4.

5.

6.

7.

8.

Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level ground.

To keep the machine stationary do not engage the parking brake, apply wedges to the rear wheels.

Turn the ignition key (2) to “0” and remove it.

Place the machine on a hoisting system (if available).

Loosen the locknuts (A) and loosen/tighten the threaded tie rod (B) as necessary. When the adjustment is completed, tighten the locknuts (A).

Lower the hoisting system (if available) and remove the machine.

Perform hands-on tests to check parking brake and brake operation.

B

A

S301631

TerraTM 3700B

146 1965 000(2)2007-02

41

ENGLISH

SERVICE MANUAL

BRAKE SYSTEM BRAKE REPLACEMENT [for machines up to serial number 062211246] 1.

2.

3.

4.

Drive the machine on a level ground without engaging the parking brake (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

CAUTION! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

5.

Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

Remove the clip (C) from the brake tie rod.

Remove the fork (D) from the brake lever (E).

Turn the wheel (I) manually, to take the junction link (M) of the chain (K) at an accessible position.

Remove the junction link (M) and release the chain (H) from the pinion of the wheel (I).

Remove the screws (K).

Remove the self-locking nut (F), then remove the wheel pin (G).

Remove the wheel assembly (I) with brake (L).

Separate the brake assembly (L) from the wheel (I).

Install the components in the reverse order of removal.

Adjust the brakes (see the procedure in the previous paragraph).

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

A

G

F

H C

M K

I

B

D E

K L S301632

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146 1965 000(2)2007-02

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SERVICE MANUAL

ENGLISH

BRAKE SYSTEM BRAKE REPLACEMENT [for machines from serial number 062211247] Disassembly Place the machine on a hoisting system (if available). Otherwise, drive the machine on a level ground.

1. To keep the machine stationary do not engage the parking brake, apply wedges to the rear wheels.

2. Turn the ignition key (2) to “0” and remove it.

3. Place the machine on a hoisting system (if available).

4. Slightly lift the machine front side, then lean it on two fixed stands in order to keep the front wheel slightly lifted.

5. Cut the fastening clamps (A).

6. Loosen the terminal (B) and remove the cable (C).

7. Turn the wheel (G) manually, to take the junction link (H) of the chain (I) at an accessible position.

8. Remove the junction link (H) and release the chain (I) from the pinion of the wheel (G).

9. Remove the screws (D).

10. Remove the self-locking nut (E), then remove the wheel pin (F).

11. Remove the wheel assembly (G) with brake (L).

12. Separate the brake assembly (L) from the wheel (G).

Assembly 13. Assemble the components in the reverse order of disassembly.

14. Adjust the brakes (see the procedure in the relevant paragraph).

F I

E

H

D

D

A

L

G

C B S301633

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ENGLISH

SERVICE MANUAL

DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only.

Preliminary operations 1.

2.

3.

4.

5.

Drive the machine on a level ground.

Turn the ignition key (2) to “0” and remove it.

Lift the machine front side, then lean its back side on two fixed stands. In this way, the front drive wheel (28) is slightly off the ground and the following test can be safely performed.

Make sure that the machine cannot move independently. If necessary, keep the machine stationary by applying wedges to the rear wheels.

Open the hood (26) and engage the hood support rod (60).

Connect the drive system motor to the battery (61) as shown in the diagram (A), by inserting the 5 A fuse (B) to protect the system.

Apply an ammeter (C) to the connection (A) and route the connection so that the hood (26) can be closed; then perform the test shown in the next step. In this way, the ammeter (C) can be seen by the operator seated on the machine.

Drive system motor electrical input check 6.

Start the machine and drive it at the maximum speed in forward and reverse gear, then measure the drive system motor electrical input in both directions with the ammeter (C).

Stop the machine and check that the readings match with the values listed in the table below.

Movement Forward Reverse

A 2.2 1.7

If the electrical input is higher, perform the following procedures to detect the cause and correct the abnormal input: • Remove dirt or foreign materials from the driving wheel drive system, which can clog or slow down its normal movement.

• If necessary, check the motor carbon brushes.

• If necessary, remove, clean and check the drive system motor.

If the above-mentioned procedures do not lead to a correct electrical input, the motor must be replaced (see the procedure in the relevant paragraph).

Reset 7.

Perform steps 3 to 5 in the reverse order.

C 5A A

B

S300827

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SERVICE MANUAL

ENGLISH

DRIVE SYSTEM DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT 1.

2.

3.

4.

5.

6.

Remove the drive system motor.

At the workbench, clean the outer part of the motor, then disengage and remove the band (A).

Lift the retaining springs (B) and remove the four carbon brushes (C).

Check the carbon brushes for wear. Replace the carbon brushes when: the contact with the motor armature is insufficient, the carbon brushes are worn, the carbon brush contact surface is not integral, the thrust spring is broken, etc.

If necessary, remove the carbon brushes to replace them, by removing the nuts (D) and disengaging the lead-in wires (E).

Replace the carbon brushes as an assembly.

Install the components in the reverse order of removal, and note the following: When connecting the terminals (E), take care of their insulation from the surrounding parts of the frame.

S300239

TerraTM 3700B

146 1965 000(2)2007-02

45

ENGLISH

SERVICE MANUAL

DRIVE SYSTEM DRIVE SYSTEM MOTOR REMOVAL/INSTALLATION 1.

2.

3.

4.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

5.

Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

6. Remove the screw (C).

7. Remove the washers (D), the pinion (E), the spacer (F) and take out the key (G).

8. Remove the screws (H) and recover the washers (I).

9. Move the reduction unit (J) and disconnect the connector (K).

10. Install the components in the reverse order of removal.

J K A C F

B

G

E

I

D

H

I H S300828

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SERVICE MANUAL

ENGLISH

DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT 1.

2.

3.

4.

7.

8.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Disconnect the connector, remove the screws (A), then remove the drive pedal (B).

At the workbench, connect the multimeter probes to black wires No. 1 and 2 on the drive pedal connector (C). Set the multimeter to Ohm. With a screwdriver (D), loosen the threaded dowel (E) locking the shaft (K) of the potentiometer (F).

Lock the actuator (G) of the microswitch (H) (if equipped*) to closed position, as shown in the figure, then check the multimeter reading is between 2,300 and 2,700 Ohm. If necessary, reset the value by turning the screw (I) with a screwdriver (J) while pressing and holding the actuator (G).

After resetting, screw down the threaded dowel (E) locking the potentiometer shaft (K).

Perform steps 3 and 4 in the reverse order.

Carry out hands-on tests to check the drive pedal operation.

*

The microswitch (H) is no longer provided on this machine after the change dated February 2005.

5.

6.

S300829

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ENGLISH

SERVICE MANUAL

DRIVE SYSTEM DRIVE PEDAL CHECK AND ADJUSTMENT (continues)

S301634

TROUBLESHOOTING THE MACHINE DOES NOT MOVE Possible causes: 1. The batteries are discharged (charge).

2. The drive system motor carbon brushes are worn (replace).

3. The drive system motor is faulty (repair/replace).

4. There are foreign materials clogging the front wheel (remove).

5. The wiring harness is damaged (repair).

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ENGLISH

OTHER SYSTEM SCREW AND NUT TIGHTENING CHECK 1.

2.

3.

4.

5.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Remove the hopper (36) as shown in the User Manual.

Open the hood (26) and engage the hood support rod (60).

Remove the batteries (61) and the battery container.

WARNING! Batteries must be removed before tilting the machine, otherwise serious damage to people or machine can occur.

6.

Check for: • Tightening of mounting screws and nuts; • Correct position of the fasteners; • Visible faults in the components; 7. Disengage the support rod (60) and close the hood (26).

8. Paying careful attention and with the help of an assistant, lift the machine front side (A), then lean its rear side on the ground (as shown in the figure), by setting it down carefully on a proper guard (B).

9. Check for: • Tightening of mounting screws and nuts; • Correct position of the fasteners; • Visible faults in the components; 10. Perform steps 3 and 8 in the reverse order.

A

B

S300835

TerraTM 3700B

146 1965 000(2)2007-02

49

ENGLISH

SERVICE MANUAL

OTHER SYSTEM FRONT COVER DISASSEMBLY/ASSEMBLY [for machines from serial number 062211247] Disassembly 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (59) and engage the hood support rod (60).

Disconnect the battery connector (63).

Disengage the support rod (60) and close the hood (59).

Remove the steering wheel cover (A) by releasing the inner fasteners.

Remove the pedal mounting screw (B).

Remove the steering wheel (D) with the puller (C) (tool No. 1463177000).

Remove the screws (E) and carefully lift the panels (F) and (G).

Disconnect the electrical system connections from the panels (F) and (G).

Lift the lever (F) by disengaging the pins (G) from the housings (H).

Remove the terminal (I) of the cable (J) from the housing of the lever (F).

Insert the cable (J) with the terminal (I) under the cover (K), by routing it through the slot (L).

Remove the rubber handles (M) and (N) from the lever.

Unscrew the knob (O) with the ring nut (P).

Remove the mounting screws (Q) and (R) of the cover (K).

Carefully lift the cover (K) and remove it.

Assembly 18. Assemble the components in the reverse order of disassembly, and note the following: • Place the steering wheel (D) with the knob (R) on the left side, with the front wheel (S) in the longitudinal position (not turned), as shown in the figure.

19. Adjust the brakes (see the procedure in the relevant paragraph).

20. Adjust the side broom height (see the procedure in the relevant paragraph).

50

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SERVICE MANUAL

ENGLISH

OTHER SYSTEM FRONT COVER DISASSEMBLY/ASSEMBLY [for machines from serial number 062211247] (continues)

S R

A

C

B D

E E G

F R K

F

Q

G I H

N

J

K

M I

P

O

J

L S301635

TerraTM 3700B

146 1965 000(2)2007-02

51

ENGLISH

SERVICE MANUAL

OTHER SYSTEM STEERING COLUMN TILTING ADJUSTING LEVER REPLACEMENT [for machines from serial number 062211247] Disassembly 1.

2.

Remove the front cover (see the procedure in the relevant paragraph).

Disconnect the steering column tilting adjusting lever (A) from the plunger (B).

Assembly 3.

Assemble the components in the reverse order of disassembly.

A

B S301636

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146 1965 000(2)2007-02

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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM BATTERY CHARGE AND MAINTENANCE See the User Manual.

BATTERY INSTALLATION AND BATTERY TYPE SETTING (WET OR GEL) Battery choice 1.

2.

3.

The machine can be equipped with the following battery types: • Lead (WET), with acid electrolyte • Gel (GEL), hermetic As for battery voltage and capacity, see the Technical Data chapter.

As for battery installation diagrams, see diagram (78).

Battery removal 4.

5.

6.

7.

8.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Disconnect the battery connector (63).

Disconnect the terminals and remove the batteries (61).

Battery installation 9.

According to the type of batteries (WET or GEL), set the machine electronic board and the battery charger, according to the following procedure:

Machine electronic board setting 10. Remove the screws (15) and carefully remove the right control panel (16).

11. On the electronic board (A), install a jumper wire (B) on WET connectors (C) for lead batteries or on GEL connectors (D) for gel batteries.

12. Carefully install the right control panel (16) and tighten the screws (5).

Battery charger setting 13.

14.

15.

16.

Turn the battery charger selector (69) to WET or GEL according to the type of batteries.

Install the batteries on the machine according to the diagram (78), then connect the cables.

Connect the battery connector (63).

Charge the batteries (see the procedure in the User Manual).

D C B A S300836

TerraTM 3700B

146 1965 000(2)2007-02

53

ENGLISH

SERVICE MANUAL

ELECTRICAL SYSTEM DRIVE SYSTEM ELECTRONIC BOARD REPLACEMEN 1.

2.

3.

4.

5.

6.

7.

8.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26) and engage the hood support rod (60).

Disconnect the battery connector (63).

Remove the screws (B), then move the fuse panel (A) carefully.

Disconnect the connections (C, D, E, F, G, H, I) from the drive system electronic board (J).

Remove the nuts (K), then remove the drive system electronic board (J).

Install the new electronic board in the reverse order of removal.

B A

S300837

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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM HOUR COUNTER AND BATTERY VOLTAGE DISPLAY ELECTRONIC BOARD REPLACEMENT 1.

2.

3.

4.

5.

6.

7.

Drive the machine on a solid and level ground and engage the parking brake with the lever (23).

Turn the ignition key (2) to “0” and remove it.

Open the hood (26). Disconnect the battery connector (63) and close the hood.

Remove the screws (15) and carefully move the right control panel (16).

Disconnect the connection (A) from the hour counter and battery voltage display electronic board (B).

Remove the screws (C), then remove the hour counter and battery voltage display electronic board (B).

Install the new electronic board in the reverse order of removal.

The new electronic board must be set according to the type of batteries (61) installed on the machine.

Install a jumper wire (D) on WET connectors (E) for lead batteries or on GEL connectors (F) for gel batteries.

A

C

C

C

F E D B

C S300838

NON-START FUNCTION CHECK (WITHOUT OPERATOR ON THE DRIVER’S SEAT) 1.

When the machine is off and the operator is not on the driver’s seat (45), try and start the machine by turning the ignition key (2) to “I”. The machine should not start.

HOOD SAFETY SWITCH OPERATION CHECK 1.

2.

3.

4.

5.

6.

7.

Open the hood (26) when the machine is off.

Try to start the machine by turning the ignition key (2) to “I”. The machine should not start.

Close the hood (26).

Start the machine by turning the ignition key (2) to “I”.

Open the hood (26). The machine should turn off immediately.

Turn the ignition key (2) to “0”.

Close the hood (26).

NON-START FUNCTION CHECK (WITH BATTERY CHARGER CONNECTED TO THE ELECTRICAL MAINS) 1.

2.

3.

When the machine is off, connect the battery charger cable (65) to the electrical mains.

Try to start the machine by turning the ignition key (2) to “I”. The machine should not start.

Disconnect the battery charger cable (65) from the electrical mains.

TerraTM 3700B

146 1965 000(2)2007-02

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ENGLISH

SERVICE MANUAL

ELECTRICAL SYSTEM COMPONENT LAYOUT NOTE The symbol in brackets after the name of the component refers to the wiring diagram (see the following page).

Key: 1. Batteries (BAT) 2. Pivoting light (BE1) 3. Reverse gear buzzer (BZ1) 4. Battery connector (C1) 5. Battery Charger (H1) 6. Hour counter and battery voltage display (EB1) 7. Drive system electronic board (EB2) 8. Starting relay (ES0) 9. Main broom switch (ES1) 10. Filter shaker relay (ES2) 11. Manual vacuum system relay (ES3) 12. Main broom/vacuum fan fuse (FA) 12a Drive system electronic board fuse (3 A) (FL) 13. Drive system fuse (FT) 14. Main fuse (key circuit) (25 A) (F1) 15. Filter shaker motor fuse (25 A) (F2) 16. Manual vacuum system fuse (40 A) (optional) (F3) 17. Horn and pivoting light fuse (10 A) (optional) (F4) 18. Working light fuse (10 A) (optional) (F5) 19. Side broom motor fuse (10 A) (F6) 20. Horn (HN1) 21. Key (K1) 22. Working light (optional) (L1) 23. Main broom motor (M1) 24. Drive system motor (M2) 25. Filter shaker motor (M3) 26. Right side broom motor (M4) 27. Left side broom motor (M5) 28. Manual vacuum system motor (optional) (M6) 29. Horn switch (P1) 30. Drive speed potentiometer (R1) 31. Hood safety switch (SWC) 32. Emergency push-button (SWS) 33. Main broom, vacuum fan and filter shaker switch (SW1) 34. Driver’s seat safety microswitch (SW2) 35. Forward/reverse gear microswitch (SW3) 36. Side broom microswitch (SW4) 37. Drive system switch (SW5) 38. Manual vacuum system switch (optional) (SW6) 39. Working light switch (SW7)

56

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ENGLISH

ELECTRICAL SYSTEM COMPONENT LAYOUT (continues)

32

21 9-33 38 39

6

29

34

30

3 36 8-10-11

22

2 35

20

26

27 24 25 S300839

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146 1965 000(2)2007-02

57

SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM COMPONENT LAYOUT (continues)

31 14-15-16-17-18-19 37 7

12a

4 12

13

1

5

28 23

S300840

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146 1965 000(2)2007-02

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SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM WIRING DIAGRAM Key: BAT: BE1: BZ1: C1: CH1: EB1: EB2: ES0: ES1: ES2: ES3: FA: FL: FT: F1: F2: F3: F4: F5: F6: HN1: K1: L1: M1: M2: M3: M4: M5: M6: P1: R1: SWC: SWS: SW1: SW2: SW4: SW5: SW6: SW7:

Batteries Pivoting light Reverse gear buzzer Battery connector Battery charger Hour counter and battery voltage display Drive system electronic board Starting relay Main broom switch Filter shaker relay Manual vacuum system relay Main broom/vacuum fan fuse Drive system electronic board fuse (3 A) Drive system fuse Main fuse (key circuit) (25 A) Filter shaker motor fuse (25 A) Manual vacuum system fuse (40 A) (optional) Horn and pivoting light fuse (10 A) (optional) Working light fuse (10 A) (optional) Side broom motor fuse (10 A) Horn Key Working light (optional) Main broom motor Drive system motor Filter shaker motor Right side broom motor Left side broom motor Manual vacuum system motor (optional) Horn switch Drive speed potentiometer Hood safety switch Emergency push-button Main broom, vacuum fan and filter shaker switch Driver’s seat safety microswitch Side broom microswitch Drive system switch Manual vacuum system switch (optional) Working light switch

Colour codes: BK: BU: BN: GN: GY: OG: PK: RD: VT: WH: YE:

Black Blue Brown Green Grey Orange Pink Red Violet White Yellow

TerraTM 3700B

146 1965 000(2)2007-02

59

60

146 1965 000(2)2007-02

TerraTM 3700B

-

+

-

+

C1

BAT

C1

BK

BK

C2(*)

F1

RD

CH

BU

C2(*)

(*) If the machine have not the optional charger (CH) installed, C2 connectors are connected togheter.

RD

BU

SWC

RD

ES0

BU

BK

85

86

WH

WH

30

87

50

K1

EB1

WH

ES0

OG

15

30

RD

SWS

BK

WHRD

WH

YE

OG

VT

BK

ES1 ES3 ES2

BUBK BN

SW6

inst.

SW1

stab.

WH

SW2

P1

BK

HN1

VTBK

PK

F4

BK

BE1

PK

BK

L1

GY

SW7

GY

F5

WH

FA

BK

M1

RD

R

BU

ES1

RD

SW4

BK

M4

RD

RD

F6

BK

M5

RD

WH

FL

RD

J1

EB2

M2

BK

3 2 1

OG BU

6 5 4

M1

RD

R1

SW5

BU

M2

B+ B-

FT

J2

BK

BZ1

RD BK

RD

R

RD

VT

ES2

BK

M3

87

30

VT

F2

RD

BK

M6

BN

ES3

BN

F3

RD

ENGLISH SERVICE MANUAL

ELECTRICAL SYSTEM WIRING DIAGRAM (continues)

S300843

SERVICE MANUAL

ENGLISH

ELECTRICAL SYSTEM

TerraTM 3700B

146 1965 000(2)2007-02

61

Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 ©2007 Nilfisk-Advance, Inc., Plymouth, MN 55447-3408 Printed in Italy