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Advance acoustic Terra 5200 B Service Manual

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Terra
5200 B
TM
SERVICE MANUAL
Advance model: 9084513010
1463546000(1)2008-07

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Summary of Contents for Advance acoustic Terra 5200 B

  • Page 1 Terra 5200 B SERVICE MANUAL Advance model: 9084513010 1463546000(1)2008-07...

  • Page 3: Table Of Contents

    SERVICE MANUAL ENGLISH TABLE OF CONTENTS GENERAL INFORMATION .............................. 3 CONVENTIONS ....................................3 MACHINE LIFTING ..................................3 MACHINE TRANSPORT ................................. 3 PUSHING OR TOWING THE MACHINE ............................3 OTHER REFERENCE MANUALS ..............................3 SAFETY ......................................3 SYMBOLS ....................................... 3 GENERAL INSTRUCTIONS ................................4 TECHNICAL DATA ...................................
  • Page 4 ENGLISH SERVICE MANUAL STEERING SYSTEM AND BRAKE SYSTEM ....................... 63 STEERING CHAIN CHECK AND CLEANING ..........................63 STEERING CHAIN REPLACEMENT ............................64 BRAKE SYSTEM ADJUSTMENT] ..............................65 BRAKE CONTROL CABLE REPLACEMENT ..........................67 BRAKE REPLACEMENT ................................69 DRIVE SYSTEM ................................71 DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK ......................

  • Page 5: General Information

    SERVICE MANUAL ENGLISH GENERAL INFORMATION GENERAL INFORMATION CONVENTIONS Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say on the driver’s seat, with the hands on the steering wheel. MACHINE LIFTING WARNING! Do not work under the lifted machine without supporting it with safety stands.

  • Page 6: General Instructions

    ENGLISH SERVICE MANUAL GENERAL INFORMATION GENERAL INSTRUCTIONS Specific warnings and cautions to inform about potential damages to people and machine are shown below. DANGER! – Before performing any maintenance, repair, cleaning or replacement procedure disconnect the battery connector, remove the ignition key and engage the parking brake. –...

  • Page 7: Technical Data

    SERVICE MANUAL ENGLISH GENERAL INFORMATION TECHNICAL DATA Dimensions and weights Values Machine length 70 in (1,776 mm) Machine width (with one side broom) 47.6 in (1,208 mm) Machine width (with two side brooms) 51.6 in (1,310 mm) Front – rear wheelbase 42.9 in (1,090 mm) Track (centres of front wheels) 38.7 in (982.7 mm)
  • Page 8 ENGLISH SERVICE MANUAL GENERAL INFORMATION Performance data Values Maximum forward speed 4.3 mi/h (7 km/h) Maximum reverse speed 2.1 mi/h (3.5 km/h) Gradeability at full load 9° (16% ) Main broom maximum speed 550 rpm Side broom maximum speed 85 rpm Panel filter surface 5580 in (3.6 m...
  • Page 9 SERVICE MANUAL ENGLISH GENERAL INFORMATION TECHNICAL DATA REFERENCE DATA AGIP ARNICA ISO-L-HV Viscosity at 104 °F (40°C) /s (mm 0.07 (45) 0.05 (32) ISO 11158 Viscosity at 212 °F (100°C) /s (mm 0,012 (7.97) 0,009 (6.40) AFNOR NF E 48603 HV Viscosity index AISE 127 Flash point COC...

  • Page 10: Dimensions

    ENGLISH SERVICE MANUAL GENERAL INFORMATION DIMENSIONS 1776 mm (70.0 in) P100256 1463546000(1)2008-07 Terra™ 5200...

  • Page 11: Scheduled Maintenance

    SERVICE MANUAL ENGLISH GENERAL INFORMATION SCHEDULED MAINTENANCE The lifespan of the machine and its maximum operating safety are ensured by proper and regular maintenance. WARNING! Before performing any maintenance procedure, carefully read the instructions shown in Safety chapter. 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.

  • Page 12: Machine Nomenclature

    ENGLISH SERVICE MANUAL 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 will be necessary to identify a component mentioned in the text. Hopper lifting/lowering/dumping enabling switch Horn switch Left side broom motor circuit breaker...
  • Page 13 SERVICE MANUAL ENGLISH GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) 11 12 13 P100250 32 41 39 44 34 P100251 Terra™ 5200 1463546000(1)2008-07...
  • Page 14 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE (Continues) P100252 1463546000(1)2008-07 Terra™ 5200...

  • Page 15: Sweeping System

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM SWEEPING SYSTEM MAIN BROOM DRIVING BELT VISUAL INSPECTION Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”. Release the fastener (33) and open the left door (32).

  • Page 16: Main Broom Driving Belt Disassembly/Assembly

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM DRIVING BELT DISASSEMBLY/ASSEMBLY Disassembly Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”. Lower the main broom lever (23). Release the fastener (33) and open the left door (32).

  • Page 17: Main Broom Pulley Bearing Replacement

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM MAIN BROOM PULLEY BEARING REPLACEMENT Disassembly Drive the machine onto an appropriate lifting hook. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”. Operating according to the safety rules, lift the machine. If the lifting hook is not available, engage the machine to the four anchors (94), and lift it with a proper hoisting system, operating according to the safety rules.

  • Page 18: Main Broom Gas Spring Disassembly/Assembly

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM GAS SPRING DISASSEMBLY/ASSEMBLY Disassembly Drive the machine onto an appropriate lifting hook. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”. Lower the main broom with the lever (23). Remove the main broom (see the procedure in the relevant paragraph).

  • Page 19: Main Broom Height Check And Adjustment

    SERVICE MANUAL ENGLISH 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 Check the main broom distance from the floor as shown below: •...
  • Page 20 ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM HEIGHT CHECK AND ADJUSTMENT (Continues) P100216 P100262 P100263 1463546000(1)2008-07 Terra™ 5200...

  • Page 21: Main Broom Replacement

    SERVICE MANUAL ENGLISH 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.

  • Page 22: Main Broom Height Adjustment Cable Replacement

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM HEIGHT ADJUSTMENT CABLE REPLACEMENT Disassembly Drive the machine onto an appropriate lifting hook. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”. Lower the main broom with the lever (23).

  • Page 23: Side Broom Height Adjustment

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM SIDE BROOM HEIGHT ADJUSTMENT NOTE Brooms with harder or softer bristles are available. This procedure is applicable to all types of brooms. Broom height adjustment Check the side broom distance from the floor as shown below: •...
  • Page 24 ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM HEIGHT ADJUSTMENT (Continues) S300526 S300527 S300528 1463546000(1)2008-07 Terra™ 5200...

  • Page 25: Side Broom Replacement

    SERVICE MANUAL ENGLISH 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 broom because there can be sharp debris between the bristles.

  • Page 26: Side Broom Lifting Cable Removal

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM LIFTING CABLE REMOVAL Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Remove the screws (A), then remove the body side (B). Lower the broom with the lever (C) or (D).

  • Page 27: Microswitch Replacement On The Side And Main Brooms Lifting Levers

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM MICROSWITCH REPLACEMENT ON THE SIDE AND MAIN BROOMS LIFTING LEVERS Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Open the hood (49) and fasten it with the support rod (63).

  • Page 28: Main Broom Motor Electrical Input Check

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Remove the main broom (see the procedure in the relevant paragraph).

  • Page 29: Main Broom Motor Carbon Brush Check And Replacement

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM MAIN BROOM MOTOR CARBON BRUSH CHECK AND REPLACEMENT Check Remove the main broom motor (see the procedure in the relevant paragraph). Remove the nuts (A) and the cover (B) at the workbench. Remove dust and dirt from the motor exterior part; then disengage and remove the clamp (C). Lift the retaining springs (D) and remove the four carbon brushes (E).

  • Page 30: Main Broom Motor Disassembly/Assembly

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM MAIN BROOM MOTOR DISASSEMBLY/ASSEMBLY Disassembly Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Remove the main broom (see the procedure in the relevant paragraph). Remove the main broom driving belt (see the procedure in the relevant paragraph).

  • Page 31: Side Broom Motor Electrical Input Check

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM SIDE BROOM MOTOR ELECTRICAL INPUT CHECK NOTE This procedure refers to the right broom: The procedure for the left broom is the same. WARNING! This procedure must be performed by qualified personnel only. Remove the side broom motor to check it (see the procedure in the relevant paragraph). WARNING! Pay attention to the brooms and the moving parts while performing the following steps.

  • Page 32: Side Broom Motor Carbon Brush Check And Replacement

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM SIDE BROOM MOTOR CARBON BRUSH CHECK AND REPLACEMENT Check Remove the motor of the side broom to be checked (see the procedure in the relevant paragraph). At the workbench, clean the outside of the motor, then mark the position (A) of the cover (B) and the motor body (C). Remove the screws (D), then carefully remove the cover (B).

  • Page 33: Side Broom Motor Removal

    SERVICE MANUAL ENGLISH SWEEPING SYSTEM SIDE BROOM MOTOR REMOVAL NOTE This procedure refers to the right broom: The procedure for the left broom is the same. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”.

  • Page 34: Troubleshooting

    ENGLISH SERVICE MANUAL SWEEPING SYSTEM TROUBLESHOOTING Open circuit The thermal fuses (FA), (FB), (FC) determine the open circuit. This system allows to prevent the broom circuits and motors from being damaged under overload conditions. If there is an open in the circuit, the possible causes are the following. Main broom motor;...

  • Page 35: Skirt

    SERVICE MANUAL ENGLISH SKIRT SKIRT SKIRT HEIGHT AND OPERATION CHECK Preliminary procedure Empty the hopper (as shown in the User Manual), because the weight of the waste inside the hopper can affect the skirt height check. Drive the machine on a level floor that is suitable for checking the skirt height. Engage the parking brake with the pedal and the lever (25 and 18).
  • Page 36 ENGLISH SERVICE MANUAL SKIRT SKIRT HEIGHT AND OPERATION CHECK (Continues) S300540 S300541 S300542 S300543 S300544 S300545 1463546000(1)2008-07 Terra™ 5200...

  • Page 37: Side Skirt Replacement

    SERVICE MANUAL ENGLISH SKIRT SIDE SKIRT REPLACEMENT Drive the machine on a level floor that is suitable for checking the skirt height. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Release the fasteners (35 and 33), then open the right and left door (34 and 32).

  • Page 38: Front Skirt Replacement

    ENGLISH SERVICE MANUAL SKIRT FRONT SKIRT REPLACEMENT Drive the machine on a level floor that is suitable for checking the skirt height. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Remove the right side broom (37) (see the procedure in the relevant paragraph).

  • Page 39: Front Skirt Control Cable Replacement

    SERVICE MANUAL ENGLISH SKIRT FRONT SKIRT CONTROL CABLE REPLACEMENT Drive the machine on a level floor that is suitable for checking the skirt height. Engage the parking brake with the pedal and the lever (26 and 19). Turn the ignition switch (17) to “0”. Remove the right side broom (38) (see the procedure in the relevant paragraph).
  • Page 40 ENGLISH SERVICE MANUAL SKIRT FRONT SKIRT CONTROL CABLE REPLACEMENT (Continues) S300549 1463546000(1)2008-07 Terra™ 5200...

  • Page 41: Dust And Debris Collection System

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM DUST AND DEBRIS COLLECTION SYSTEM PANEL 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.
  • Page 42 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM PANEL DUST FILTER CLEANING AND INTEGRITY CHECK (Continues) P100225 S300551 S300552 S300553 1463546000(1)2008-07 Terra™ 5200...

  • Page 43: Closed Pocket Filter Cleaning And Integrity Check

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM CLOSED POCKET FILTER CLEANING AND INTEGRITY CHECK NOTE The polyester closed pocket filters are normally kept clean by using the filter shaker supplied with the machine. If necessary, they can be cleaned externally according to the following procedure. When the filtration surfaces are no longer suitable, the filter must be replaced.
  • Page 44 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM CLOSED POCKET FILTER CLEANING AND INTEGRITY CHECK (Continues) P100225 S310186 S310187 S310145 1463546000(1)2008-07 Terra™ 5200...

  • Page 45: Vacuum Fan Motor Electrical Input Check

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM VACUUM FAN MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Open the hood (49) and fasten it with the support rod (63).

  • Page 46: Vacuum Fan Motor Removal/Replacement

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM VACUUM FAN MOTOR REMOVAL/REPLACEMENT Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Open the hood (49) and fasten it with the support rod (63).

  • Page 47: Filter Shaker Operation Check

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM FILTER SHAKER OPERATION CHECK During machine operation, when the panel filter is supposed to be clogged, turn off the vacuum system with the switch (6), then press the filter shaker switch (6) and check that the typical noise is audible. Restart the machine and check that the filter has been properly shaken.

  • Page 48: Hopper Gasket Check And Replacement

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER GASKET CHECK AND REPLACEMENT NOTE A poor integrity of the hopper gaskets can affect the machine vacuuming capabilities. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) completely (see the procedure in the User Manual).
  • Page 49 SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER GASKET CHECK AND REPLACEMENT (Continues) S300559 Terra™ 5200 1463546000(1)2008-07...

  • Page 50: Horizontal Hopper Control Microswitch Check And Adjustment

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HORIZONTAL HOPPER CONTROL MICROSWITCH CHECK AND ADJUSTMENT CHECK Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) (see the procedure in the User Manual) until the side microswitch (A) is accessible. Partially turn the hopper (31) (see the procedure in the User Manual), then lower it and check that this operation is inhibited, otherwise the microswitch (A) must be adjusted according to the following procedure.

  • Page 51: Horizontal Hopper Control Microswitch Replacement

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HORIZONTAL HOPPER CONTROL MICROSWITCH REPLACEMENT Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) (see the procedure in the User Manual) until the side microswitch (A) is accessible. Turn the ignition switch (17) to “0”.

  • Page 52: Lifted Hopper Control Microswitch Check And Adjustment

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM LIFTED HOPPER CONTROL MICROSWITCH CHECK AND ADJUSTMENT Check Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) (see the procedure in the User Manual) until it reaches the position (A). In this position try to dump the hopper and confirm that the procedure cannot be performed.
  • Page 53 SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM LIFTED HOPPER CONTROL MICROSWITCH CHECK AND ADJUSTMENT (Continues) S300564 Terra™ 5200 1463546000(1)2008-07...

  • Page 54: Lifted Hopper Control Microswitch Replacement

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM LIFTED HOPPER CONTROL MICROSWITCH REPLACEMENT Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) (see the User Manual) until it reaches the position (A); then turn the ignition switch (17) to “0”. Apply a proper safety stand under the lifted hopper to prevent it from lowering incidentally.

  • Page 55: Hopper Rotation Actuator Check And Adjustment

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER ROTATION ACTUATOR CHECK AND ADJUSTMENT Check Remove the main broom (see the procedure in the relevant paragraph). Slightly lift the hopper (31) (see the procedure in the User Manual); then lower the hopper (31) again but stop it when the upper rear side (A) is at 0.8 in (2 cm) (B) from the machine frame.
  • Page 56 ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER ROTATION ACTUATOR CHECK AND ADJUSTMENT (Continues) S300567 S300568 1463546000(1)2008-07 Terra™ 5200...

  • Page 57: Hopper Rotation Actuator Replacement

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER ROTATION ACTUATOR REPLACEMENT Lift the hopper (31) in order that the hopper rotation actuator (A) is high enough to allow adjustment (for hopper handling, see the procedure in the User Manual). Apply a proper safety stand under the lifted hopper to prevent it from lowering incidentally.

  • Page 58: Hopper Mechanical Stabilizer Check And Adjustment

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER MECHANICAL STABILIZER CHECK AND ADJUSTMENT Check Lift the hopper (31) in order that the hopper mechanical stabilizer (A) is high enough to allow adjustment (for hopper handling, see the procedure in the User Manual). WARNING! The hopper (31) can lower accidentally.

  • Page 59: Hopper Removal

    SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER REMOVAL Lift the hopper (31) in order that it is high enough to allow operation on its fasteners (for hopper handling, see the procedure in the User Manual). WARNING! The hopper (31) can lower accidentally. Place a stand under the hopper to support it when detached.

  • Page 60: Adjustment Hopper End-Of-Stroke [Sr 1301 B/Sr 1301 P]

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM ADJUSTMENT HOPPER END-OF-STROKE [SR 1301 B/SR 1301 P] Check WARNING! This procedure must be performed by qualified personnel only. NOTE Failure adjustment of hopper end-of-stroke affects the functionality of the dust collecting system and the main broom motor.
  • Page 61 SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM ADJUSTMENT HOPPER END-OF-STROKE [SR 1301 B/SR 1301 P] (Continues) S300559 Terra™ 5200 1463546000(1)2008-07...

  • Page 62: Hopper Lifting Lever Assembly Removal

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM HOPPER LIFTING LEVER ASSEMBLY REMOVAL Remove the hopper (see the procedure in the relevant paragraph). On both sides of the machine, remove the screws (A), then remove the body sides (B). Disconnect the connectors (C) from the relevant electrical cables (D). Remove the electrical cables (D) from the duct (E).
  • Page 63 SERVICE MANUAL ENGLISH DUST AND DEBRIS COLLECTION SYSTEM HOPPER LIFTING LEVER ASSEMBLY REMOVAL (Continues) L310005 Terra™ 5200 1463546000(1)2008-07...

  • Page 64: Troubleshooting

    ENGLISH SERVICE MANUAL DUST AND DEBRIS COLLECTION SYSTEM TROUBLESHOOTING Open circuit The relays and the lamellar fuses in the box (56) determine the open circuit. This system allows to prevent the motor circuits from being damaged under overload conditions. If there is an open in the circuit, the possible causes are the following. Vacuum fan motor: The relevant lamellar fuse in the box (56) burns and opens the electrical circuit.

  • Page 65: Steering System And Brake System

    SERVICE MANUAL ENGLISH STEERING SYSTEM AND BRAKE SYSTEM STEERING SYSTEM AND BRAKE SYSTEM STEERING CHAIN CHECK AND CLEANING NOTE The steering chain is not adjustable. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”.

  • Page 66: Steering Chain Replacement

    ENGLISH SERVICE MANUAL STEERING SYSTEM AND BRAKE SYSTEM STEERING CHAIN REPLACEMENT NOTE The steering chain is not adjustable. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. By turning the steering wheel, take the steering chain junction link (A) at an accessible position.

  • Page 67: Brake System Adjustment

    SERVICE MANUAL ENGLISH STEERING SYSTEM AND BRAKE SYSTEM BRAKE SYSTEM ADJUSTMENT Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently.
  • Page 68 ENGLISH SERVICE MANUAL STEERING SYSTEM AND BRAKE SYSTEM BRAKE ADJUSTMENT (Continues) S300577 1463546000(1)2008-07 Terra™ 5200...

  • Page 69: Brake Control Cable Replacement

    SERVICE MANUAL ENGLISH STEERING SYSTEM AND BRAKE SYSTEM BRAKE CONTROL CABLE REPLACEMENT Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently.
  • Page 70 ENGLISH SERVICE MANUAL STEERING SYSTEM AND BRAKE SYSTEM BRAKE CONTROL CABLE REPLACEMENT (Continues) S300579 1463546000(1)2008-07 Terra™ 5200...

  • Page 71: Brake Replacement

    SERVICE MANUAL ENGLISH STEERING SYSTEM AND BRAKE SYSTEM BRAKE REPLACEMENT NOTE The following procedure refers to the right brake replacement; the procedure to replace the left brake is the same. Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently, applying wedges (Z) to the left wheel.
  • Page 72 ENGLISH SERVICE MANUAL STEERING SYSTEM AND BRAKE SYSTEM BRAKE REPLACEMENT (Continues) S300580 1463546000(1)2008-07 Terra™ 5200...

  • Page 73: Drive System

    SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently.
  • Page 74 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK (Continues) S300581 1463546000(1)2008-07 Terra™ 5200...

  • Page 75: Drive System Motor Carbon Brush Check And Replacement

    SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Open the hood (49) and fasten it with the support rod (63).

  • Page 76: Drive System Motor Removal

    ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR REMOVAL Disassembly Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) completely. Turn the ignition switch (17) to “0”. Apply a proper safety stand under the lifted hopper to prevent it from lowering incidentally.
  • Page 77 SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM MOTOR REMOVAL (Continues) LUBRICANT OIL TABLE Ambient temperature 86°F ÷ 149°F (+30°C ÷ +65°C) ISO VG Viscosity Viscosity °E/50°C 15 ÷ 18 AGIP - IP MELLANA - BLASIA 220 BP-MACH ENERGOL GR-HP220 CASTROL ALPHA SP 220 CHEVRON NL GEAR COMPOUND 220...
  • Page 78 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR REMOVAL (Continues) S300585 S300586 1463546000(1)2008-07 Terra™ 5200...

  • Page 79: Driveshaft Bearing Replacement

    SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVESHAFT BEARING REPLACEMENT Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (31) completely (see the procedure in the User Manual). Turn the ignition switch (17) to “0”.
  • Page 80 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVESHAFT BEARING REPLACEMENT (Continues) S300589 S300590 1463546000(1)2008-07 Terra™ 5200...

  • Page 81: Drive Chain Cleaning And Tension Check

    SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE CHAIN CLEANING AND TENSION CHECK Cleaning and tension check Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently.
  • Page 82 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE CHAIN CLEANING AND TENSION CHECK (Continues) S300592 S300593 1463546000(1)2008-07 Terra™ 5200...

  • Page 83: Drive Chain Replacement

    SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE CHAIN REPLACEMENT CAUTION! It is advisable to replace both chains at the same time. Drive the machine on a level floor. Do not engage the parking brake with the pedal and the lever (25 and 18), but make sure that the machine cannot move independently.
  • Page 84 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE CHAIN REPLACEMENT (Continues) S300595 1463546000(1)2008-07 Terra™ 5200...

  • Page 85: Forward/Reverse Gear Pedal Control Board Replacement

    SERVICE MANUAL ENGLISH DRIVE SYSTEM FORWARD/REVERSE GEAR PEDAL CONTROL BOARD REPLACEMENT Drive the machine on a level floor. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Remove the forward/reverse gear pedal mounting screws (A). Remove the cover (B).
  • Page 86 ENGLISH SERVICE MANUAL DRIVE SYSTEM FORWARD/REVERSE GEAR PEDAL CONTROL BOARD REPLACEMENT (Continues) S300597 1463546000(1)2008-07 Terra™ 5200...

  • Page 87: Troubleshooting

    SERVICE MANUAL ENGLISH DRIVE SYSTEM TROUBLESHOOTING The machine does not move Possible causes: The motor carbon brushes are worn (replace). The motor is faulty (repair or replace). There are foreign materials clogging the drive chain (remove). The under-seat switch is damaged (replace). The potentiometric accelerator is damaged (replace).
  • Page 88 ENGLISH SERVICE MANUAL 1463546000(1)2008-07 Terra™ 5200...

  • Page 89: Hopper Hydraulic Lifting System

    SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM HOPPER HYDRAULIC LIFTING SYSTEM HYDRAULIC SYSTEM OIL CHANGE CAUTION! Replacement to be performed with the hopper (31) fully retracted (as shown in the figure). Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”.
  • Page 90 ENGLISH SERVICE MANUAL HOPPER HYDRAULIC LIFTING SYSTEM HYDRAULIC SYSTEM OIL CHANGE (Continues) S300598 P100293 1463546000(1)2008-07 Terra™ 5200...
  • Page 91 SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM HYDRAULIC SYSTEM OIL CHANGE (Continues) S300600 Terra™ 5200 1463546000(1)2008-07...

  • Page 92: Hopper Lifting System Pump Removal

    ENGLISH SERVICE MANUAL HOPPER HYDRAULIC LIFTING SYSTEM HOPPER LIFTING SYSTEM PUMP REMOVAL Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Ensure that the hopper (31) is fully retracted. WARNING! While removing the pump, the hopper (31) should not be in the lifted position or in intermediate positions, even if the hopper lifting hydraulic cylinder is equipped with a parachute valve which prevents the hopper from...
  • Page 93 SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM HOPPER LIFTING SYSTEM PUMP REMOVAL (Continues) S300602 Terra™ 5200 1463546000(1)2008-07...

  • Page 94: Hopper Lifting Hydraulic Cylinder Removal

    ENGLISH SERVICE MANUAL HOPPER HYDRAULIC LIFTING SYSTEM HOPPER LIFTING HYDRAULIC CYLINDER REMOVAL Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Lift the hopper (A) partially, as shown in the figure, until the hydraulic cylinder upper fork (B) is accessible (see the procedure in the User Manual).
  • Page 95 SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM HOPPER LIFTING HYDRAULIC CYLINDER REMOVAL (Continues) P100294 S300604 L310010 Terra™ 5200 1463546000(1)2008-07...

  • Page 96: Pump-To-Hydraulic Cylinder Feed And/Or Return Hoses Removal

    ENGLISH SERVICE MANUAL HOPPER HYDRAULIC LIFTING SYSTEM PUMP-TO-HYDRAULIC CYLINDER FEED AND/OR RETURN HOSES REMOVAL (Continues) Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Ensure that the hopper (A) is completely retracted. WARNING! While removing the pump, the hopper (31) should not be in the lifted position or in intermediate positions, even if the hopper lifting hydraulic cylinder is equipped with a parachute valve which prevents the hopper from...
  • Page 97 SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM PUMP-TO-HYDRAULIC CYLINDER FEED AND/OR RETURN HOSES REMOVAL (Continues) P100295 S300607 S300608 Terra™ 5200 1463546000(1)2008-07...

  • Page 98: Component Location

    ENGLISH SERVICE MANUAL HOPPER HYDRAULIC LIFTING SYSTEM COMPONENT LOCATION Oil tank Oil filter Pump Motor Parachute valve Hopper hydraulic lifting cylinder S300609 1463546000(1)2008-07 Terra™ 5200...

  • Page 99: Hydraulic Diagram

    SERVICE MANUAL ENGLISH HOPPER HYDRAULIC LIFTING SYSTEM HYDRAULIC DIAGRAM Oil tank Oil filter Pump Motor Parachute valve Hopper hydraulic lifting cylinder 200 BAR 200 BAR 110 BAR 70 BAR 750cc / HYDRAULIC OIL 32 cSt P100210 Terra™ 5200 1463546000(1)2008-07...
  • Page 100 ENGLISH SERVICE MANUAL 1463546000(1)2008-07 Terra™ 5200...

  • Page 101: Other Systems

    SERVICE MANUAL ENGLISH OTHER SYSTEMS OTHER SYSTEMS SCREW AND NUT TIGHTENING CHECK Drive the machine on a level floor. Engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition switch (17) to “0”. Open the hood (79) and fasten it with the support rod (73). Disconnect the battery connector (52).
  • Page 102 ENGLISH SERVICE MANUAL 1463546000(1)2008-07 Terra™ 5200...

  • Page 103: Electrical System

    SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM ELECTRICAL SYSTEM BATTERY REMOVAL, INSTALLATION, MAINTENANCE AND CHARGING See the User Manual. FUSE CHECK/REPLACEMENT/RESET Drive the machine on a level floor and engage the parking brake with the pedal and the lever (25 and 18). Turn the ignition key (17) to “0”.

  • Page 104: Drive System Electronic Board Replacement

    ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM DRIVE SYSTEM ELECTRONIC BOARD REPLACEMENT NOTE After installing a new drive system electronic board installation, neither the machine nor the electronic board should be reprogrammed. Drive the machine on a level floor and engage the parking brake with the pedal and the lever (26 and 19). Turn the ignition switch (17) to “0”.

  • Page 105: Troubleshooting

    SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM TROUBLESHOOTING In case of drive system malfunction, check if the drive system electronic board diagnostic warning light (E) turns on. Check the number of flashes and refer to the following table: No. of flashes Description Causes and remedies Pedal pressed upon ignition.

  • Page 106: Component Location

    ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LOCATION Flashing light (optional) Reverse gear buzzer/horn Battery connector Drive system electronic board Display electronic board Line electromagnetic switch Main broom electromagnetic switch Hopper lifting pump relay Hopper lowering pump relay Vacuum system relay Main fuse (150 A) Key fuse (30 A) Filter shaker fuse (30 A)
  • Page 107 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) R1-SW1 SW15 SW16 SW13 SW14 SW12 SW11 SW10 P100296 Terra™ 5200 1463546000(1)2008-07...
  • Page 108 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LOCATION (Continues) ES3-ES4 BATT P100297 1463546000(1)2008-07 Terra™ 5200...

  • Page 109: Wiring Diagram

    SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM Colour code Flashing light (optional) Black Reverse gear buzzer/horn Blue Battery connector Brown Drive system electronic board Green Display electronic board Grey Line electromagnetic switch Orange Main broom electromagnetic switch Pink Hopper lifting pump relay Hopper lowering pump relay Violet Vacuum system relay...

  • Page 110: Terra

    ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) P100248 1463546000(1)2008-07 Terra™ 5200...
  • Page 111 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM (Continues) P100248 Terra™ 5200 1463546000(1)2008-07...
  • Page 112 Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 ©2008 Nilfisk-Advance, Inc., Plymouth, MN 55447-3408 Printed in Italy...

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