BA 450/530 BA 5321 SERVICE MANUAL

BA 450/530 BA 5321 SERVICE MANUAL 08812876(1)2002-01

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 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 08812876(1)2002-01 49

GB SERVICE MANUAL 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 50 08812876(1)2002-01

SERVICE MANUAL GB GENERAL INFORMATION GENERAL INFORMATION MACHINE LIFTING WARNING! Do not work under the lifted machine if it is not securely fixed. MACHINE TRANSPORTATION 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 MACHINE PUSHING OR TOWING 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. 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 08812876(1)2002-01 51

GB SERVICE MANUAL GENERAL INFORMATION 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. 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. GENERAL SAFETY RULES Specific warnings and cautions to inform about potential damages to people and machine are shown below. 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. 52 08812876(1)2002-01

SERVICE MANUAL GB GENERAL INFORMATION 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 08812876(1)2002-01 53

998 GB SERVICE MANUAL GENERAL INFORMATION 560,5 443 770 1078,5 BA 450 = 1250 BA 530 / CA 5321 = 1330 Dimensions expressed by mm S300161 54 08812876(1)2002-01

SERVICE MANUAL GB GENERAL INFORMATION MAINTENANCE SCHEDULED MAINTENANCE The machine proper and safe operation is granted by a careful and constant maintenance. See GENERAL INFORMATION and SAFETY - ACCIDENT PREVENTION The following table sums up the scheduled maintenance. The indicated periods can be subjected to variations according to working conditions. These must be defined by the person in charge for the maintenance. For maintenance operation instructions see the following paragraphs. 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 08812876(1)2002-01 55

GB SERVICE MANUAL GENERAL INFORMATION 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 56 08812876(1)2002-01

SERVICE MANUAL GB GENERAL INFORMATION MACHINE NOMENCLATURE (CONTINUE) S300163 08812876(1)2002-01 57

GB SERVICE MANUAL DETERGENT SUPPLY SYSTEM 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). Remark: The wire gauze (B) must be correctly positioned on the support (C) housing (D). 4. Carry out step 1. and 2. in the reverse order. Figure 1 S300164 58 08812876(1)2002-01

SERVICE MANUAL GB DETERGENT SUPPLY SYSTEM 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). Remark: For the BA 5321 (USA) version, disconnect the solenoid valve (D1) cables by removing the screw (P) and disconnecting the electrical connection (R). 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). 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. 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). 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. 18. Install in the reverse order of removal. Figure 2 S300165 08812876(1)2002-01 59

GB SERVICE MANUAL DETERGENT SUPPLY SYSTEM 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 Figure 4 S300166 S300167 60 08812876(1)2002-01

SERVICE MANUAL GB DETERGENT SUPPLY SYSTEM 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). 08812876(1)2002-01 61

GB SERVICE MANUAL SWEEPING SYSTEM SWEEPING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. 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). WARNING! Pay attention to the brush flange rotation while performing the following steps. 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. Figure 1 Figure 2 C 30A D S300169 S300168 62 08812876(1)2002-01

SERVICE MANUAL GB SWEEPING SYSTEM 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). CAUTION! When reinstalling, take care of assemble the bearing (H) with the smaller side (M) facing the pinion (as shown in the figure). 14. Remove the wire gauze (L). 15. Install in the reverse order of removal. Figure 3 Figure 4 S300171 S300170 08812876(1)2002-01 63

GB SERVICE MANUAL SWEEPING SYSTEM 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 Figure 6 S300172 S300173 64 08812876(1)2002-01

BRUSH REDUCTION UNIT REPLACEMENT (Continue) Figure 7 SERVICE MANUAL GB SWEEPING SYSTEM S300174 08812876(1)2002-01 65

GB SERVICE MANUAL SWEEPING SYSTEM 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. CAUTION! If the micro-switch electrical connections (N) have been disconnected, take care to connect them again correctly. 12. Install in the reverse order of removal. 13. Carry out some tests to check the brush rotation consent. Figure 8 Figure 9 S300175 S300176 66 08812876(1)2002-01

SERVICE MANUAL GB SWEEPING SYSTEM TROUBLESHOOTING OPEN CIRCUIT The thermal fuse (35) determines the open circuit. This system allows to prevent the brush motor circuits from being damaged under overload conditions. If there is an open in the electrical circuit, the possible causes are the following. Brush motor; the thermal fuse (35) activates and opens the electrical circuit. Possible cause: 1. There are bulky debris or cords around the brush or between the brush and its flange (remove the brush and the debris or cords). 2. The brush motor electrical input is too high (check the electrical input). Wait at least 2 minutes after the break and, when the problem is solved, push the thermal fuse button (35). THE BRUSH DOES NOT ROTATE Possible cause: 1. To avoid damaging the floor, the brush motor turns off automatically when the machine stands still in the same position (the brush cannot stand still in the same position). 2. The battery voltage is to low (charge the battery). 3. The electrical motor brushes are worn (replace the electrical motor brushes). 4. The electrical motor has a malfunction (repair or replace the electrical motor). 5. The thermal fuse (35) is deactivated (remove the cause of deactivation). 6. The brush ON/OFF switch (3) is broken (replace it). 7. The reduction unit has a malfunction (repair or replace it). 8. The brush rotation consent micro-switch is not correctly adjusted or is broken (adjust or replace it). 9. The wiring harness is damaged (repair it). 10. The electromagnetic switch is broken (replace it). 08812876(1)2002-01 67

GB SERVICE MANUAL RECOVERY SYSTEM RECOVERY SYSTEM FLOAT SHIELD AND SUCTION PRE-FILTER CLEANING 1. Drive the machine on a level ground. 2. Turn the switch key (2) to OFF position. 3. Lift the cover (24) of the tanks. 4. If necessary drain the water from the recovery tank (11) through the pipe (25) to visually inspect the shield (A). 5. Check that the shield (A) and the float (B) are clean; if necessary disengage the retainers (C), open the shield and clean it. Then place them into their correct position and engage the retainers. 6. Lift the cover (D) and check that the pre-filter (E) is clean; if necessary clean it with water and then with compressed air. Then place the filter and the cover into their correct position. 7. Carry out step 1., 2., 3. in the reverse order. Figure 1 S300177 68 08812876(1)2002-01

SUCTION PRE-FILTER ASSEMBLY REPLACEMENT SERVICE MANUAL GB RECOVERY SYSTEM 1. Drive the machine on a level ground. 2. Turn the switch key (2) to OFF position. 3. Lift the cover (24) of the tanks. 4. Drain all the water from the recovery tank (11) through the pipe (25). 5. Disengage the retainers (A) and open the shield (B) by disengaging it from the pre-filter assembly. Recover the float (C). 6. Rotate the pre-filter assembly (D) in the direction indicated by the arrow to disengage the four retainers (E) from their housings, then remove it upwards, overcoming the gasket (F) resistance. 7. Clean the tank housing (G) and the new pre-filter assembly area (H). 8. In the area (H) apply a thin coat of AREXONS spray silicone (silicon waterproofing lubricant). 9. Carry out step 5. and 6. in the reverse order. 10. Lift the cover (I) and check that the pre-filter (L) is clean. 11. Carry out step 1., 2., 3. in the reverse order. Figure 2 S300178 08812876(1)2002-01 69

GB SERVICE MANUAL RECOVERY SYSTEM TANK COVER GASKET AND COMPENSATION HOLE CHECK 1. Drive the machine on a level ground. 2. Turn the switch key (2) to OFF position. 3. Lift the cover (24) of the tanks. 4. Check that the tank cover gasket (A) is clean. Remark: The gasket (A) creates suction pressure that is necessary for the suction of recovery water. If necessary replace the gasket (A) after removing it from its housing (B). When assembling the new gasket, install its joint (C) as shown in the figure. 5. Check that the gasket (A) seal surface (D) is integral and adequate for the gasket. 6. Check that the compensation hole (E) is not obstructed. Remark: The hole (E), allowing to compensate the air in the cover interspaces, contributes to create suction pressure. 7. Carry out step 1., 2., 3. in the reverse order. Figure 3 S300179 70 08812876(1)2002-01

SERVICE MANUAL GB RECOVERY SYSTEM SUCTION MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. 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. To operate on the suction motor (15) carefully lift the tank assembly (27) by means of the maneuver handle (30). WARNING! Do not touch uncovered electrical components while performing the following steps. 7. Apply amperometric pliers (A) on a cable of the suction motor (B). 8. Activate the suction motor by means of the button (4) and check that the motor electrical input is about 20 A at 24 V. If the electrical input is greater carry out the motor brush check (see the procedure on the following pages). If necessary, disassemble the suction motor (see the procedure on the following page), clean it and 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). 9. Carry out steps from 1. to 7. in the reverse order. Figure 4 S300180 08812876(1)2002-01 71

GB SERVICE MANUAL RECOVERY SYSTEM SUCTION MOTOR REMOVAL 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. To operate on the suction motor (15) carefully lift the tank assembly (27) by means of the maneuver handle (30). 7. Disconnect the battery (22) negative cable (-). 8. Disconnect the suction motor (D) electrical cables (B and C) from the connection (A). 9. Remove the motor fastening screws (E). 10. Remove the suction motor (D) and the joint (F). 11. Recover the gasket (G) that is between the motor and the structure. 12. Install in the reverse order of removal. Figure 5 S300181 72 08812876(1)2002-01

SERVICE MANUAL GB RECOVERY SYSTEM SUCTION MOTOR BRUSH/CARBON BRUSH CHECK AND 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. To operate on the suction motor (15) carefully lift the tank assembly (27) by means of the maneuver handle (30). 7. Disconnect the battery (22) negative cable (-). 8. Remove the cover (A) (that is pressurized) from the suction motor (B). 9. Remove the brushes (C). 10. Check if the brushes are worn. The brushes are worn when there is not sufficient contact with the motor armature, because of their use, of the contact surface which is not integral or because the thrust spring is broken, etc. 11. If necessary, remove the brushes to replace them, by disengaging the lead-in wires (D). It is advisable to replace all the brushes at the same time. 12. Install in the reverse order of removal. Figure 6 S300182 08812876(1)2002-01 73

GB SERVICE MANUAL RECOVERY SYSTEM RECOVERY WATER DRAIN PIPE REMOVAL 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 retaining flange (A) inside the tank (11). 6. Remove the key (28) from its housing and remove the tank assembly fastening screw (29). 7. Carefully lift the tank assembly (27) by means of the maneuver handle (30). 8. Pull out the terminal (B) from the tank and remove the recovery water drain pipe (C). 9. Before reinstalling the recovery water drain pipe, clean the hole (E). Ensure that the gasket (D) is present, then warm its end (B) with hot water (to make it become softer) and insert it in the hole (E). 10. Carry out step 6. and 7. in the reverse order. 11. Install the retaining flange (A) after applying on its surface (F) a thin coat of AREXONS spray silicone (silicone waterproofing lubricant). 12. Carry out steps from 1. to 4. in the reverse order. Figure 7 Figure 8 S300183 S300184 74 08812876(1)2002-01

SERVICE MANUAL GB RECOVERY SYSTEM RECOVERY SYSTEM SUCTION CAP CHECK/CLEANING AND POSSIBLE FLAPS REPLACEMENT 1. Drive the machine on a level ground. 2. Turn the switch key (2) to OFF position. 3. Lower the suction cap assembly (23) by means of the handle (9). 4. Disconnect the suction pipe (A) from the suction cap (C) and from the tank (Q); check that the internal part of the pipe is free from dirt; otherwise clean it. 5. Remove the handwheels (B) and the suction cap assembly (C). 6. Check that the hole (D) and the spaces (E) are free from dirt; otherwise clean them. 7. Check that the edges (I) of the front and rear flaps (F and G) lay down on the same level, along their length; otherwise adjust their height as described below: Disengage the retainer (L) and loosen the screws (M) to adjust the rear flap (G); then tighten the screws and engage the retainer. Loosen the nuts (N) to adjust the front flap (F); then tighten the nuts. 8. Check that the front and rear flap (F and G) are integral and free from cuts and lacerations; otherwise replace them as described below. Check that the front corner (H) of the rear flap is not worn; if the rear corner is integral overturn the flap. If the rear corner is worn, replace the flap as described below: To replace (or overturn) the rear flap (G) disengage the retainer (L), remove the screws (M) and the retaining strip (O). Install in the reverse order of removal. To replace the front flap (F) remove the nuts (N) and the retaining strip (P). Install in the reverse order of removal. After the flap replacement (or overturning), adjust their height as described by the previous step. 9. Reinstall the suction cap assembly (C) in the correct position and screw down the handwheels (B). 10. Connect the suction pipe (A) to the suction cap (C) and to the tank (Q). 11. If necessary, adjust the balancing handwheel (R) of the suction cap. Figure 9 S300185 08812876(1)2002-01 75

GB SERVICE MANUAL RECOVERY SYSTEM RECOVERY SYSTEM SUCTION CAP CHECK/CLEANING AND POSSIBLE FLAPS REPLACEMENT (Continue) Figure 10 SISTEMA DI RACCOLTA DETRITI E POLVERE DUST AND DEBRIS COLLECTION SYSTEM SUCTION CAP REMOVAL 1. Drive the machine on a level ground. 2. Turn the switch key (2) to OFF position. 3. Lower the suction cap assembly (23) by means of the handle (9). 4. Disconnect the suction pipe (A) from the suction cap (B). 5. Remove the handwheels (C) and the suction cap assembly (B). 6. Install in the reverse order of removal and, if necessary, adjust the balancing handwheel (D) of the suction cap. Figure 11 S300186 S300187 76 08812876(1)2002-01

SERVICE MANUAL GB RECOVERY SYSTEM RECOVERY SYSTEM TROUBLESHOOTING OPEN CIRCUIT The thermal fuse (36) determines the open circuit. This system allows to prevent the suction motor circuits from being damaged under overload conditions. If there is an open in the electrical circuit, the possible causes are the following. Suction motor; the thermal fuse (36) activates and opens the electrical circuit. Possible cause: 1. The motor is damaged (check the motor brushes/electrical input). Wait at least 2 minutes after the break and, when the problem is solved, push the thermal fuse button (36). DIRTY WATER SUCTION IS INSUFFICIENT OR THERE IS NO SUCTION Possible cause: 1. The float automatic closing (12) is activated because the water recovery tank (11) is too full (empty the water recovery tank). 2. The float shield (12) or the suction filter are dirty (clean them). 3. The tank cover (24) is not correctly positioned (place it correctly). 4. The tank cover gasket is not efficient or the compensating hole is obstructed (remove the causes). 5. The suction cap or suction pipe obstructed or damaged (clean/repair/replace them) 6. The battery voltage is to low (charge the battery). 7. The Electrical motor brushes are worn (replace the electrical motor brushes). 8. The electrical motor has a malfunction (repair or replace the electrical motor). 9. The thermal fuse (36) is deactivated (remove the cause of deactivation). 10. The suction ON/OFF switch (4) is broken (replace it). 11. The wiring harness is damaged (repair it). 12. The suction motor electromagnetic switch is broken (replace it). THE SUCTION CAP LEAVES LINING OR DOES NOT COLLECT WATER Possible cause: 1. There is debris under the suction cap lip (remove them) 2. The suction cap flap lips are torn or worn (replace the flaps) 3. The suction cap is unbalanced (balance it by means of the handwheel (38)). 08812876(1)2002-01 77

GB SERVICE MANUAL TRACTION SYSTEM SYSTEM TRACTION MOTOR ELECTRICAL INPUT CHECK WARNING! This procedure must be performed by qualified personnel only. 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 electronic case cover (B). Disconnect the traction motor (D) cables (C) from the connection (I) (electrical symbol T4) to the electronic board and from the connection (L). 12. Lift the driving wheels (E) a few centimeters from the ground by inserting adequate shims under the brush (18) or under the front wheel (32). Then securely fix the machine in this position so that the driving wheels (E) can turn freely without touching the ground during the following tests. WARNING! Pay attention to the driving wheel (E) rotation while performing the following steps. 13. Connect the traction motor to the machine battery, as described in the underlying diagram, inserting the 10 A fuse (F), for safety s sake. 14. With an ammeter check that the motor electrical input is about 3-4 A at 24 V. If the electrical input is greater carry out the motor brush check (see the procedure on the following pages). If necessary, disassemble the traction motor (see the procedure on the following page), clean it and 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). 15. Carry out steps from 1. to 12. in the reverse order. 78 08812876(1)2002-01

TRACTION MOTOR ELECTRICAL INPUT CHECK (Continue) Figure 1 SERVICE MANUAL GB TRACTION SYSTEM Figure 2 S300188 G 10A F S300189 08812876(1)2002-01 79

GB SERVICE MANUAL TRACTION SYSTEM TRACTION MOTOR REMOVAL 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. Remove the screws (A) and the electronic case cover (B). Disconnect the traction motor (D) cables (C) from the connection (M) (electrical symbol T4) to the electronic board and from the connection (N). 14. Carefully lower the tank assembly (27) by means of the maneuver handle (30). 15. Remove the left wheel (F) and the snap ring (G). 16. Lay down the machine on one side and set it down carefully on proper guards (H). 17. Remove the right wheel (I). 18. Remove the four screws (L). 19. Remove the motor assembly with the reduction unit (D). 20. Install in the reverse order of removal. Figure 3 S300190 80 08812876(1)2002-01

SERVICE MANUAL GB TRACTION SYSTEM TRACTION MOTOR REMOVAL (Continue) Figure 4 Figure 5 S300191 S300192 08812876(1)2002-01 81

GB SERVICE MANUAL TRACTION SYSTEM TRACTION MOTOR BRUSH (OR CARBON BRUSH) CHECK AND 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. Carefully lower the tank assembly (27) by means of the maneuver handle (30). 14. Lay down the machine on one side and set it down carefully on proper guards (A). 15. Carefully open the tank assembly (I) completely by means of the maneuver handle (30). 16. Remove the two screws (B) and lightly slide the tap-solenoid valve assembly (C). 17. Clean the exterior part of the traction motor (L) from dirty and dust, then mark the reciprocal position (D) between the cover (E) and the motor body. 18. Remove the screws (F) and the cover (E). 19. Check if the two brushes (G) are worn. The brushes are worn when there is not sufficient contact with the motor armature, because of their use, of the contact surface which is not integral or because the thrust spring is broken, etc. 20. If necessary, remove the brushes to replace them, by disengaging the lead-in wires (H). It is advisable to replace all the brushes at the same time. 21. Install in the reverse order of removal. Figure 6 S300193 82 08812876(1)2002-01

SERVICE MANUAL GB TRACTION SYSTEM SYSTEM TRACTION MOTOR BRUSH (OR CARBON BRUSH) CHECK AND REPLACEMENT (Continue) Figure 7 S300194 08812876(1)2002-01 83

GB SERVICE MANUAL TRACTION SYSTEM POTENTIOMETER 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. Connect a 20KOhm tester to the connections (D and E) of the potentiometer (G) and check the following values under the following conditions: With the activation panel (C) deactivated: 2.40 2.60 KOhm With the activation panel (C) in the forward limit switch position: 4.80 5.00 KOhm With the activation panel (C) in the backward limit switch position: 0.00 0.25 KOhm CAUTION! Pay attention not to invert the connecting cables to the potentiometer (G) electrical connections (D, E, F) 11. To obtain the above conditions, loosen the screw (H) and turn the potentiometer shaft (I) as necessary. Tighten the screw. If necessary, loosen the screws (L) and adjust the cam (M) position. 12. Carry out steps from 1. to 9. in the reverse order. 13. Carry out speed change tests Figure 8 Figure 9 S300175 S300195 84 08812876(1)2002-01

SERVICE MANUAL GB TRACTION SYSTEM TROUBLESHOOTING OPEN CIRCUIT Possible cause: 1. There are bulky debris or cords under the machine or around the driving wheels (remove the debris). 2. The motor is damaged (check the motor brushes/electrical input). 3. The slope is excessive (drive only on the maximum slope allowed) Wait at least 2 minutes after the break and, when the problem is solved, push the thermal fuse button (34). THE MACHINE DOES NOT MOVE Other possible cause: 1. The battery voltage is to low (charge the battery). 2. The potentiometer inside the activation panel (8) is misadjusted or broken (adjust or replace it). 3. The potentiometer (1) is broken (replace it). 4. The traction electronic board has a malfunction (replace it). 5. The thermal fuse (34) is deactivated (remove the cause of deactivation). 6. The wiring harness is damaged (repair it). 7. The switch (39) is to OFF position. 08812876(1)2002-01 85

GB SERVICE MANUAL ELECTRICAL SYSTEM ELECTRICAL SYSTEM BATTERY REMOVAL 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. If necessary, remove the battery frame (31). 11. Install in the reverse order of removal. BATTERY MAINTENANCE AND RECHARGING See Use and Maintenance Manual TRACTION ELECTRONIC BOARD REPLACEMENT REMARK: It is not necessary to perform the electronic programming of the new boards. 1. Remove the batteries (See the previous procedure). 2. Remove the screws (A) and the electronic case cover (B). 3. Disconnect all the electrical connections of the board (C) (See the wiring diagram). 4. Remove the screws (D) and the traction electronic board (C). 5. Install in the reverse order of removal. Figure 1 S300196 86 08812876(1)2002-01

ELECTRICAL SYSTEM SERVICE ELECTRONIC BOARD REPLACEMENT SERVICE MANUAL GB ELECTRICAL SYSTEM REMARK: It is not necessary to perform the electronic programming of the new board. 1. Remove the batteries (See the previous procedure). 2. Remove the screws (A) and the electronic case cover (B). 3. Disconnect all the electrical connections of the board (C) (See the wiring diagram). 4. Disengage the retainers (D) and remove the service electronic board (C). 5. Install in the reverse order of removal. Figure 2 S300197 08812876(1)2002-01 87

GB SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the electrical system. Other possible malfunction causes are: 1. The battery is discharged or its connections are not efficient (charge the battery or clean the connections). 2. The battery charger is not efficient (replace it). 3. The thermal fuses are deactivated (activate them). 4. The wiring harness is cut or shorted to ground (repair it) 5. The safety micro-switch (41) is not efficient (replace it). COMPONENT LAYOUT 1. Batteries 2. Brush motor 3. Brush motor switch 4. Battery charger 5. Reset thermal fuse 6. Traction motor 7. Battery type switch 8. Hour counter 9. Ignition key switch 10. Electromagnetic switch 11. Brush rotation consent micro-switch 12. Traction speed control potentiometer (5KOhm) 13. Traction speed control potentiometer (47KOhm) 14. Relay electronic board (services) 15. Traction control electronic board 16. Detergent supply solenoid valve 17. Traction switch 18. Suction motor 19. Suction motor switch 88 08812876(1)2002-01

SERVICE MANUAL GB ELECTRICAL SYSTEM Figure 3 S300198 08812876(1)2002-01 89

GB SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM BA 450/530 - after serial number 014106978 With traction with battery charger 08812796 S300199 90 08812876(1)2002-01

SERVICE MANUAL GB ELECTRICAL SYSTEM WIRING DIAGRAM BA 450/530 - after serial number 014106978 Without traction with battery charger 08812797 S300200 08812876(1)2002-01 91

GB SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM BA 450/530 - after serial number 014106978 With traction without battery charger 08812798 S300201 92 08812876(1)2002-01

SERVICE MANUAL GB ELECTRICAL SYSTEM WIRING DIAGRAM BA 450/530 - after serial number 014106978 Without traction without battery charger 08812799 S300202 08812876(1)2002-01 93

GB SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM BA 5321 - after serial number 1514570 S300203 94 08812876(1)2002-01

WIRING DIAGRAM BA 5321D - after serial number 1514570 SERVICE MANUAL GB ELECTRICAL SYSTEM S300204 08812876(1)2002-01 95

GB SERVICE MANUAL ELECTRICAL SYSTEM FINE 96 08812876(1)2002-01

Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 2002 Nilfisk-Advance, Inc., Plymouth, MN 55447-3408 Printed in the U.S.A.