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
GB
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
GB
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
GB
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
SERVICE MANUAL
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
SERVICE MANUAL
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 SUPPLY 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
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