Nilfisk-Advance BA 450 User manual

BA 450/530

BA 5321

08812876(1)2002-01

SERVICE MANUAL

Nilﬁsk-Advance Italia S.p.A

Località Novella Terza

26862 Guardamiglio (Lodi) Italia

www.nilﬁsk-advance.com

Phone: +39 0377 451124

Fax: +39 0377 51443

Printed in Italy

SERVICE MANUAL

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08812876(1)2002-01 49

INDEX

GENERAL INFORMATION 51

MACHINE LIFTING 51

MACHINE TRANSPORTATION 51

MACHINE PUSHING OR TOWING 51

OTHER AVAILABLE MANUALS FOR BA 450/530 51

SAFETY - ACCIDENT PREVENTION 52

GENERAL SAFETY RULES 52

TECHNICAL DATA 53

MAINTENANCE 55

SCHEDULED MAINTENANCE 55

MACHINE NOMENCLATURE 56

DETERGENT SUPPLY SYSTEM 58

DETERGENT TANK AND SUPPLY SYSTEM CLEANING 58

DETERGENT FILTER CLEANING 58

SOLENOID VALVE AND DETERGENT FLOW TAP REPLACEMENT 59

DETERGENT FLOW CABLE AND CONTROL LEVER REPLACEMENT 60

TROUBLESHOOTING 61

SMALL AMOUNT OF THE DETERGENT OR NO DETERGENT REACHES THE BRUSH 61

THE DETERGENT REACHES THE BRUSH ALSO WHEN THE MACHINE IS OFF 61

SWEEPING SYSTEM 62

BRUSH MOTOR ELECTRICAL INPUT CHECK 62

BRUSH MOTOR REPLACEMENT 63

BRUSH REDUCTION UNIT REPLACEMENT 64

BRUSH ROTATION CONSENT MICRO-SWITCH ADJUSTMENT 66

TROUBLESHOOTING 67

OPEN CIRCUIT 67

THE BRUSH DOES NOT ROTATE 67

RECOVERY SYSTEM 68

FLOAT SHIELD AND SUCTION PRE-FILTER CLEANING 68

SUCTION PRE-FILTER ASSEMBLY REPLACEMENT 69

TANK COVER GASKET AND COMPENSATION HOLE CHECK 70

SUCTION MOTOR ELECTRICAL INPUT CHECK 71

SUCTION MOTOR REMOVAL 72

SUCTION MOTOR BRUSH/CARBON BRUSH CHECK AND REPLACEMENT 73

RECOVERY WATER DRAIN PIPE REMOVAL 74

SUCTION CAP CHECK/CLEANING AND POSSIBLE FLAPS REPLACEMENT 75

DUST AND DEBRIS COLLECTION SYSTEM SUCTION CAP REMOVAL 76

TROUBLESHOOTING 77

DIRTY WATER SUCTION IS INSUFFICIENT OR THERE IS NO SUCTION 77

THE SUCTION CAP LEAVES LINING OR DOES NOT COLLECT WATER 77

TRACTION SYSTEM 78

TRACTION MOTOR ELECTRICAL INPUT CHECK 78

TRACTION MOTOR REMOVAL 80

TRACTION MOTOR BRUSH (OR CARBON BRUSH) CHECK AND REPLACEMENT 82

POTENTIOMETER ADJUSTMENT 84

TROUBLESHOOTING 85

OPEN CIRCUIT 85

THE MACHINE DOES NOT MOVE 85

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50 08812876(1)2002-01

ELECTRICAL SYSTEM 86

BATTERY REMOVAL 86

BATTERY MAINTENANCE AND RECHARGING 86

TRACTION ELECTRONIC BOARD REPLACEMENT 86

ELECTRICAL SYSTEM 87

SERVICE ELECTRONIC BOARD REPLACEMENT 87

TROUBLESHOOTING 88

COMPONENT LAYOUT 88

WIRING DIAGRAM BA 450/530 - after serial number 014106978 90

WIRING DIAGRAM BA 5321 - after serial number 1514570 94

WIRING DIAGRAM BA 5321D - after serial number 1514570 95

SERVICE MANUAL

GENERAL INFORMATION

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08812876(1)2002-01 51

GENERAL INFORMATION

MACHINE LIFTING

MACHINE TRANSPORTATION

MACHINE PUSHING OR TOWING

OTHER AVAILABLE MANUALS FOR BA 450/530

The following manuals are available by Nilfisk Literature Service Department:

–BA 450/530 Part List – Nilfisk Form Number 08603654(2)00-12

–BA 450/530 Use and Maintenance Manual.- Nilfisk Form Number 08812382(2)2001-03

WARNING!

Do not work under the lifted machine if it is not securely fixed.

WARNING!

Before transporting the machine, ensure that:

•All doors and carters are closed

•The ignition key is not inserted

•The machine is fastened to the mean of transportation

WARNING!

Do not move the machine by pushing or towing it, unless you follow the procedures described

in the Use and Maintenance Manual. If you do not follow the specified procedures the machine

can be damaged.

SERVICE MANUAL

GENERAL INFORMATION

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52 08812876(1)2002-01

SAFETY - ACCIDENT PREVENTION

Nilfisk uses the following symbols to indicate potentially dangerous situations. Always read carefully this

information and take the necessary precautions to protect people and objects.

GENERAL SAFETY RULES

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

DANGER!

Indicates the risk of being injured or the risk of death.

WARNING!

Indicates the risk of being injured.

CAUTION!

Indicates the risk of light injuries to people, machine or other objects.

WARNING!

To perform maintenance/repair procedures, put the machine on a flat floor, turn the ignition key

to OFF position and disconnect the battery.

This machine must be used by qualified and authorized personnel only.

Keep the battery far from sparks, flames and smoke. During the normal operation explosive

gases are delivered.

Do not wear jewels when working near electrical components.

Do not work under the lifted machine if it is not securely fixed.

Do not operate the machine near inflammable liquids or vapors.

CAUTION!

Carefully read all maintenance/repair instructions before carrying out any maintenance/repair

procedure.

Take all necessary precautions to prevent hair, jewels and loose dresses from being caught by

the machine moving parts.

Battery charging produces explosive hydrogen gas. Charge the batteries only in good ventilated

areas and far from naked flames.

Do not smoke during battery charging.

Do not leave the machine unattended on an inclined floor.

Do not use the machine on slopes with an inclination higher than 2%.

Do not wash the machine with pressurized water.

Do not use the machine in too dusty areas.

This machine is not suitable for picking up hazardous dust.

If the temperature is below 0°, the water present into the reservoirs and into the pipes of the

machine could freeze.

During the use of this machine take care not to cause damage to people and children especially.

This machine cannot be used on public roads.

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GENERAL INFORMATION

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08812876(1)2002-01 53

TECHNICAL DATA

Dimensions

BA 450 BA 530 BA 5321

Suction width 30 in (770 mm) 30 in (770 mm) 30 in (770 mm)

Sweeping width 17.7 in (450 mm) 20.8 in (530 mm) 20.8 in (530 mm)

Machine length 49 in (1250 mm) 52 in (1330 mm) 52 in (1330 mm)

Machine height at the maneuver handle 42.5 in (1078.5 mm) 42,5 in (1078,5 mm) 42,5 in (1078,5 mm)

Brush dimension Ø 450 mm (17.7 in) Ø 530 mm (20.8 in) Ø 530 mm (20.8 in)

Brush speed 180 RPM 180 RPM 180 RPM

Brush pressure on the floor 34 Kg 27 kg 27 kg

Forward maximum speed (*) 4.5 km/h 4.5 km/h 4.5 km/h

Reverse maximum speed (*) 2.2 km/h 2.2 km/h 2.2 km/h

Max slope 2 % 2 % 2 %

Detergent tank capacity 13.2 gal (55 liters) 13.2 gal (55 liters) 13.2 gal (55 liters)

Recovery water tank capacity 13.2 gal (55 liters) 13.2 gal (55 liters) 13.2 gal (55 liters)

Machine weight (without batteries) 134 kg 134 kg 134 kg

Machine weight (with standard batteries) 215 kg 215 kg 215 kg

Standard battery weight 81 Kg 81 Kg 81 Kg

Batteries

Standard batteries (no. 2 batteries) 12 Volt, 100 Ah 12 Volt, 100 Ah 12 Volt, 100 Ah

Battery voltage 24 V 24 V 24 V

Battery housing, dimensions

Height 295 mm (11.5 in) 295 mm (11.5 in) 295 mm (11.5 in)

Width 345 mm (13.5 in) 345 mm (13.5 in) 345 mm (13.5 in)

Length 350 mm (13.5 in) 350 mm (13.5 in) 350 mm (13.5 in)

General technical characteristics

Electrical system voltage 24 V 24 V 24 V

Brush motor 650 W - 1600 RPM 650 W - 1600 RPM 650 W - 1600 RPM

Suction motor 500 W - 3300 RPM 500 W - 3300 RPM 500 W - 3300 RPM

Traction motor 200 W - 120 RPM 200 W - 120 RPM 200 W - 120 RPM

Dirty water suction pressure 13 kPa 13 kPa 13 kPa

Air intake 31 l/sec 31 l/sec 31 l/sec

(*) BA 450/530 with traction motor only

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GENERAL INFORMATION

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54 08812876(1)2002-01

S300161

Dimensions expressed by mm

998

560,5

443

770

BA 450 = 1250

BA 530 / CA 5321 = 1330

1078,5

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GENERAL INFORMATION

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08812876(1)2002-01 55

MAINTENANCE

SCHEDULED MAINTENANCE

The machine proper and safe operation is granted by a careful and constant maintenance.

The following table sums up the scheduled maintenance. The indicated periods can be subjected to variations

according to working conditions. These must be defined by the person in charge for the maintenance.

For maintenance operation instructions see the following paragraphs.

See GENERAL INFORMATION and SAFETY - ACCIDENT PREVENTION

Maintenance operation On delivery After use

(daily)

Every 25

hours (or

weekly)

Every 100

hours

Every 200

hours

Battery charging •

Battery liquid level and voltage

(Volt) • •

Suction cap cleaning/check •

Float shield and suction pre-filter

cleaning •

Tank cover gasket check

(vacuum chamber) •

Detergent tank and supply

system cleaning •

Detergent filter cleaning •

Hose and tank inspection •

Nut and screw tightening check •

Electric suction motor brush (or

carbon brush) check and

replacement •

Electric traction motor brush (or

carbon brush) check and

replacement •

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GENERAL INFORMATION

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56 08812876(1)2002-01

MACHINE NOMENCLATURE

In this Manual you find numbers in brackets – example: (2). These numbers refer to the components indicated in

the two nomenclature pages. Refer to these pages each time you want to find the component mentioned in the

text.

1. Speed control potentiometer (*)

2. Main switch with key (*)

3. Brush switch

4. Suction switch

5. Battery condition indicator

6. Detergent flow control lever

7. Hour counter

8. Start/Stop activation panel

9. Suction cap lifting/lowering handle

10. Brush lifting/lowering pedal

11. Water recovery tank

12. Recovery tank automatic closing with float

13. Suction pre-filter

14. Detergent tank

15. Suction motor

16. Brush motor

17. Traction adjusting handles

18. Brush

19. Integrated battery charger (**)

20. Circuit panel

21. Traction motor (*)

22. Batteries

23. Suction cap assembly

24. Tank covers

25. Recovery water drain pipe

26. Detergent drain pipe

27. Tank assembly

28. Key (supplied with the machine)

29. Tank assembly fastening screw

30. Machine maneuver handle

31. Battery frame

32. Front wheel

33. Driving wheels (*)

34. Traction motor thermal fuse

35. Brush motor thermal fuse

36. Suction motor thermal fuse

37. Brush reduction unit

38. Suction cap balancing adjustment handwheel

39. Traction switch (*)

(*) BA 450/530 with traction motor only

(**) Optional

S300162

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GENERAL INFORMATION

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08812876(1)2002-01 57

MACHINE NOMENCLATURE (CONTINUE)

S300163

SERVICE MANUAL

DETERGENT SUPPLY SYSTEM

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58 08812876(1)2002-01

DETERGENT S UPPLY SYSTEM

DETERGENT TANK AND SUPPLY SYSTEM CLEANING

1. Empty the detergent tank (14) through the pipe (26).

2. Take the detergent flow control lever (6) in wide-open position, then activate the machine until the detergent

inside the machine is exhausted.

3. Carry out the Detergent filter cleaning (see the following procedure).

DETERGENT FILTER CLEANING

1. Drive the machine on a level ground.

2. Turn the switch key (2) to OFF position.

3. Operating on the left lower side of the machine, remove the cover (A) and the wire gauze (B), clean and install

them again on the related support (C).

4. Carry out step 1. and 2. in the reverse order.

Figure 1

S300164

Remark: The wire gauze (B) must be correctly positioned on the support (C) housing (D).

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DETERGENT SUPPLY SYSTEM

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08812876(1)2002-01 59

SOLENOID VALVE AND DETERGENT FLOW TAP REPLACEMENT

1. Drive the machine on a level ground.

2. Turn the switch key (2) to OFF position.

3. If there is recovery water in the tank (11) remove it through the pipe (25).

4. If there is detergent in the tank (14) remove it through the pipe (26).

5. Remove the key (28) from its housing and remove the tank assembly fastening screw (29).

6. Carefully lift the tank assembly (27) by means of the maneuver handle (30).

7. Disconnect the battery (22) negative cable (-).

8. Disconnect the other cables of the batteries.

9. Remove the batteries (22).

10. Remove the battery frame (31).

11. Remove the screws (A) and the cover (B) of the electronic case, then disconnect the solenoid valve (D)

cables (C) from the electronic board connections (E) (connection electrical symbols: F1 and F4).

12. Disconnect the hoses (F and G).

13. Remove the solenoid valve (D) fastening screws (H).

14. Disconnect the tap (M) control lever (L) cable (I). If necessary loosen the cable sheath (O) fixing clamp (N).

15. Remove the solenoid valve assembly (D) with the tap (M).

16. Remove the pipe unions (Q and S) at the cabinet bench.

17. Remove the tap (M) from the solenoid valve (D).

18. Install in the reverse order of removal.

Figure 2

S300165

Remark: For the BA 5321 (USA) version, disconnect the solenoid valve (D1) cables by removing

the screw (P) and disconnecting the electrical connection (R).

Remark: When reinstalling, fix the sheath (O) by means of the clamp (N) in the same position (see

the print on the sheath); in this way the adjustment of the tap control remains unchanged.

Remark: when reinstalling the solenoid valve (D), the stamping orientation (T) must be as shown

in the figure; moreover, before installing the unions (Q and S) and the tap (M) clean the related

threads and apply LOCTITE 572 sealant.

SERVICE MANUAL

DETERGENT SUPPLY SYSTEM

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60 08812876(1)2002-01

DETERGENT FLOW CABLE AND CONTROL LEVER REPLACEMENT

1. Drive the machine on a level ground.

2. Turn the switch key (2) to OFF position.

3. Operating under the machine left side, loosen the sheath (D) fixing clamp (C) and disconnect the cable (A)

from the tap lever (B).

4. Disconnect the sheath (D) from the fixing clamps along its run up to the lever (6).

5. Remove the handgrip (F) from the lever (G).

6. Remove the screws (H) and lightly slide the panel (I).

7. Remove the screws (L) and the control lever with the cable (M).

8. Install in the reverse order of removal and adjust the sheath terminal (D) position so that when the tap lever

(B) is in the position shown in the figure (closed) the control lever (G) is in “zero” flow position. When the lever

(G) is in maximum flow position, the lever (B) rotates about 90°.

Figure 3

S300166

Figure 4

S300167

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DETERGENT SUPPLY SYSTEM

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08812876(1)2002-01 61

TROUBLESHOOTING

SMALL AMOUNT OF THE DETERGENT OR NO DETERGENT REACHES THE BRUSH

Possible cause:

1. The brush switch (3) is not to ON position or it is broken (turn it on or repair/replace it).

2. The detergent filter is obstructed/dirty (clean it).

3. The detergent flow control lever does not control the related tap anymore (check the control lever cable, from

the lever to the tap).

4. The detergent tap is stuck closed (replace the tap).

5. The solenoid valve is broken or there is an open circuit in the electrical connection (replace the solenoid

valve/repair the electrical connection).

6. There is debris in the detergent tank obstructing the output hole (clean the tank).

7. There is debris in the detergent pipeline obstructing the detergent flow (clean the pipeline).

THE DETERGENT REACHES THE BRUSH ALSO WHEN THE MACHINE IS OFF

Possible cause:

1. The solenoid valve is broken (replace it).

SERVICE MANUAL

SWEEPING SYSTEM

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62 08812876(1)2002-01

SWEEPING SYSTEM

BRUSH MOTOR ELECTRICAL INPUT CHECK

1. Remove the brush (18).

2. Drive the machine on a level ground.

3. Turn the switch key (2) to OFF position.

4. If there is recovery water in the tank (11) remove it through the pipe (25).

5. If there is detergent in the tank (14) remove it through the pipe (26).

6. Remove the key (28) from its housing and remove the tank assembly fastening screw (29).

7. To operate on the brush motor (16) carefully lift the tank assembly (27) by means of the maneuver handle

(30).

8. Disconnect the battery (22) negative cable (-).

9. Disconnect the motor electrical cables (A) from the connection (B).

10. Connect the brush motor to the machine battery, as described in the underlying diagram, inserting the 30 A

fuse (D), for safety’s sake.

11. By means of an ammeter (C) check that the brush motor electrical input is 8-9 A at 24 V. If the input is greater,

disassemble the motor (see the procedure on the following page), clean the motor properly and then check

its moving parts.

If the above-mentioned procedures do not lead to a correct motor input it is necessary to replace the motor

(see the procedure on the following page).

12. Carry out steps from 1. to 9. in the reverse order.

WARNING!

This procedure must be performed by qualified personnel only.

WARNING!

Pay attention to the brush flange rotation while performing the following steps.

Figure 1

S300168

Figure 2

S300169

C

D

30A

SERVICE MANUAL

SWEEPING SYSTEM

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08812876(1)2002-01 63

BRUSH MOTOR REPLACEMENT

1. Remove the brush (18).

2. Drive the machine on a level ground.

3. Turn the switch key (2) to OFF position.

4. If there is recovery water in the tank (11) remove it through the pipe (25).

5. If there is detergent in the tank (14) remove it through the pipe (26).

6. Remove the key (28) from its housing and remove the tank assembly fastening screw (29).

7. To operate on the brush motor (16) carefully lift the tank assembly (27) by means of the maneuver handle

(30).

8. Disconnect the battery (22) negative cable (-).

9. Disconnect the motor electrical cables (A) from the connection (B).

10. Cut the clamp (C).

11. Remove the nuts (D) and the brush motor (E).

12. Remove the spring pin (F) and the pinion (G) at the cabinet bench.

13. Remove the bearing (H) and the gasket (I).

14. Remove the wire gauze (L).

15. Install in the reverse order of removal.

CAUTION!

When reinstalling, take care of assemble the bearing (H) with the smaller side (M) facing the

pinion (as shown in the figure).

Figure 3

S300170

Figure 4

S300171

SERVICE MANUAL

SWEEPING SYSTEM

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64 08812876(1)2002-01

BRUSH REDUCTION UNIT REPLACEMENT

1. Remove the brush (18).

2. Drive the machine on a level ground.

3. Remove the suction cap (see the related paragraph).

4. Turn the switch key (2) to OFF position.

5. If there is recovery water in the tank (11) remove it through the pipe (25).

6. If there is detergent in the tank (14) remove it through the pipe (26).

7. Remove the key (28) from its housing and remove the tank assembly fastening screw (29).

8. Carefully lift the tank assembly (27) by means of the maneuver handle (30).

9. Disconnect the battery (22) negative cable (-).

10. Disconnect the other cables of the batteries.

11. Remove the batteries (22).

12. Remove the battery frame (31).

13. Disconnect the detergent pipe (A).

14. Disconnect the motor electrical cables (B) from the connection (C).

15. Cut the clamp (D).

16. Carefully lower the tank assembly (27) by means of the maneuver handle (30).

17. Lay down the machine on one side and set it down carefully on proper guards (E).

18. Carefully open the tank assembly (27) completely by means of the maneuver handle (30).

19. Operating on the brush installation area, remove the screw (G), the flange assembly (H) and recover the key

(I).

20. Remove the screws (L) and the reduction unit with the motor (M).

21. Remove the detergent pipe fixed on the holes (N).

22. Remove the three nuts (O) and separate the brush motor (P) from the reduction unit (Q).

23. Install in the reverse order of removal.

CAUTION!

Before installing the new reduction unit, fill in with oil of the type and quantity indicated by the

reduction unit data plate.

Figure 5

S300172

Figure 6

S300173

SERVICE MANUAL

SWEEPING SYSTEM

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08812876(1)2002-01 65

BRUSH REDUCTION UNIT REPLACEMENT (Continue)

Figure 7

S300174

SERVICE MANUAL

SWEEPING SYSTEM

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66 08812876(1)2002-01

BRUSH ROTATION CONSENT MICRO-SWITCH ADJUSTMENT

1. Drive the machine on a level ground.

2. Turn the switch key (2) to OFF position.

3. If there is recovery water in the tank (11) remove it through the pipe (25).

4. If there is detergent in the tank (14) remove it through the pipe (26).

5. Remove the key (28) from its housing and remove the tank assembly fastening screw (29).

6. Carefully lift the tank assembly (27) by means of the maneuver handle (30).

7. Disconnect the battery (22) negative cable (-).

8. Carefully lower the tank assembly (27) by means of the maneuver handle (30).

9. Remove the screws (A) and the activation panel (C) cover (B).

10. With the activation panel (C) deactivated, check that the micro-switch (E) actuator (D) is in the cam (I)

housing (F).

11. Activate the panel (C) and check that the actuator (D) is at the positions (G and H) and activates the

micro-switch (E) (a “click” must be heard).

If necessary, reach the required condition by loosening the screws (L) and adjusting the cam position (I)

and/or loosening the screws (M) and adjusting the micro-switch position (E). Tighten the screws.

12. Install in the reverse order of removal.

13. Carry out some tests to check the brush rotation consent.

Figure 8

S300175

Figure 9

S300176

CAUTION!

If the micro-switch electrical connections (N) have been disconnected, take care to connect them

again correctly.

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Nilfisk-Advance BA 450 User manual

Nilfisk-Advance BA 450 User manual

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