Advance acoustic BA 5321 User manual

BA 5321/D - BA 6124D
SERVICE MANUAL
Advance Models:
08838130 - 08838135 from serial number 1640309
08603992(1)2003-06
908 7014 020

Nilfisk-Advance, Inc.
14600 21st Avenue North
Plymouth, MN, 55447-3408
www.nilfisk-advance.com
Phone: [phone]
Fax: [phone]
©2003 Nilfisk-Advance, Inc.,
Plymouth, MN 55447-3408
Printed in Italy

SERVICE MANUAL
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08603992(1)2003-06 1
INDEX
GENERAL INFORMATION 3
MACHINE LIFTING 3
MACHINE TRANSPORTATION 3
MACHINE PUSHING OR TOWING 3
OTHER AVAILABLE MANUALS 3
SAFETY - ACCIDENT PREVENTION 4
GENERAL SAFETY RULES 4
TECHNICAL DATA 5
MAINTENANCE 7
SCHEDULED MAINTENANCE 7
MACHINE NOMENCLATURE 8
DETERGENT SUPPLY SYSTEM 10
DETERGENT TANK AND SUPPLY SYSTEM CLEANING 10
DETERGENT FILTER CLEANING 10
SOLENOID VALVE AND DETERGENT FLOW TAP REPLACEMENT 11
DETERGENT FLOW CABLE AND CONTROL LEVER REPLACEMENT 12
TROUBLESHOOTING 13
SMALL AMOUNT OF THE DETERGENT OR NO DETERGENT REACHES THE BRUSH 13
THE DETERGENT REACHES THE BRUSH ALSO WHEN THE MACHINE IS OFF 13
SWEEPING SYSTEM 14
BRUSH MOTOR ELECTRICAL INPUT CHECK (BA 5321/D Only) 14
BRUSH MOTOR ELECTRICAL INPUT CHECK (BA 6124D Only) 15
BRUSH MOTOR REPLACEMENT (BA 5321/D Only) 17
BRUSH MOTOR REPLACEMENT (BA 6124D Only) 19
BRUSH MOTOR BRUSHES (OR CARBON BRUSHES) CHECK AND REPLACEMENT (BA 5321/D Only) 22
BRUSH MOTOR BRUSHES (OR CARBON BRUSHES) CHECK AND REPLACEMENT (BA 6124D Only) 23
BRUSH BELT CHECK (BA 6124D Only) 24
BRUSH BELT REPLACEMENT AND HEAD BEARINGS CHECK (BA 6124D Only) 25
BRUSH REDUCTION UNIT REPLACEMENT (BA 5321/D Only) 28
BRUSH ROTATION CONSENT MICRO-SWITCH ADJUSTMENT 33
TROUBLESHOOTING 34
OPEN CIRCUIT 34
THE BRUSH DOES NOT ROTATE 34
RECOVERY SYSTEM 35
FLOAT SHIELD AND SUCTION PRE-FILTER CLEANING 35
SUCTION PRE-FILTER ASSEMBLY REPLACEMENT 36
TANK COVER GASKET AND COMPENSATION HOLE CHECK 37
SUCTION MOTOR ELECTRICAL INPUT CHECK 38
SUCTION MOTOR REMOVAL 39
SUCTION MOTOR BRUSH/CARBON BRUSH CHECK AND REPLACEMENT 40
SUCTION MOTOR BRUSH/CARBON BRUSH CHECK AND REPLACEMENT 41
RECOVERY WATER DRAIN PIPE REMOVAL 42
PULIZIA/CONTROLLO VENTOSA DI ASPIRAZIONE ED EVENTUALE SOSTITUZIONE DEI FLAP 43
SUCTION CAP CHECK/CLEANING AND POSSIBLE FLAPS REPLACEMENT 44
SUCTION CAP REMOVAL 44
RECOVERY SYSTEM 45
TROUBLESHOOTING 45
DIRTY WATER SUCTION IS INSUFFICIENT OR THERE IS NO SUCTION 45
THE SUCTION CAP LEAVES LINING OR DOES NOT COLLECT WATER 45

SERVICE MANUAL
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208603992(1)2003-06
TRACTION SYSTEM 46
DRIVE MOTOR ELECTRICAL INPUT CHECK 46
DRIVE MOTOR REMOVAL 48
DRIVE MOTOR BRUSH (OR CARBON BRUSH) CHECK AND REPLACEMENT 50
POTENTIOMETER ADJUSTMENT 52
TROUBLESHOOTING 53
OPEN CIRCUIT 53
THE MACHINE DOES NOT MOVE 53
ELECTRICAL SYSTEM 54
BATTERY REMOVAL 54
BATTERY MAINTENANCE AND RECHARGING 54
TRACTION ELECTRONIC BOARD REPLACEMENT 54
SERVICE ELECTRONIC BOARD REPLACEMENT 55
ELECTRONIC BOARD CONTROLLING THE BRUSH MOTOR OPERATION CHECK
AND REPLACEMENT (BA 6124D Only)) 56
TROUBLESHOOTING 58
COMPONENT LAYOUT 58
BA 5321 WIRING DIAGRAM 60
WIRING DIAGRAM BA 5321D 61
WIRING DIAGRAM BA 6124D 62

SERVICE MANUAL
GENERAL INFORMATION
GB
08603992(1)2003-06 3
GENERAL INFORMATION
MACHINE LIFTING
MACHINE TRANSPORTATION
MACHINE PUSHING OR TOWING
OTHER AVAILABLE MANUALS
The following manuals are available by Advance Literature Service Department:
– BA 5321/D - BA 6124D Part List – Form Number 08812649
– BA 5321/D - BA 6124D Instructions for Use - Form Number 08812648
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
408603992(1)2003-06
SAFETY - ACCIDENT PREVENTION
Advance 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 !
Drive the machine on a level ground; to perform maintenance/repair procedures turn the
machine 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 performing any maintenance/repair
procedure.
Take all necessary precautions to prevent hair, jewels and loose clothes from being caught by
the machine moving parts.
Battery charging produces explosive hydrogen gas. Charge the batteries only in well-ventilated
areas and far from naked flames.
Do not smoke during battery charging.
Do not leave the machine unattended on slopes with the ignition key still inserted.
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 collecting dangerous powders.
Take care when the machine gets under the freezing temperature, because the water inside tanks
and pipes can freeze.
While using this machine, take care not to cause damage to people and children especially.
This machine cannot be used on public roads.

SERVICE MANUAL
GENERAL INFORMATION
GB
08603992(1)2003-06 5
TECHNICAL DATA
Dimensions
BA 5321/D - BA 6124D BA 5321/D BA 6124D
Suction width 770 mm (30 in) 812 mm (32 in)
Sweeping width 530 mm (20.8 in) 610 mm (24 in)
Machine length 1330 mm (52 in) 1311 mm (51.61 in)
Machine height at the maneuver
handle 1078.5 mm (42.5 in) 1078 mm (42.4 in)
Brush dimension ø530 mm (20.8 in) ø305 mm (12 in)
Brush speed 180 RPM 220 RPM
Brush pressure on the floor 27 kg (60 lbs) 35.5 kg (78 lbs)
Forward maximum speed (*) 4.5 km/h (2.8 mph) (*) 4.5 km/h (2.8 mph)
Detergent tank capacity 55 liters (13.2 gal) 55 liters (13.2 gal)
Recovery water tank capacity 55 liters (13.2 gal) 55 liters (13.2 gal)
Machine weight (without batteries) 134 kg (296 lbs) 150 kg (330 lbs)
Batteries
Standard batteries (no. 2 batteries) 12 Volt, 100 Ah 12 Volt, 100 Ah
General technical characteristics
Electrical system voltage 24 V 24 V
Brush motor 650 W 650 W
Suction motor 500 W 500 W
Drive motor (*) 200 W (*) 200 W
Dirty water suction pressure 13 kPa (56.9 in/water) 13 kPa (56.9 in/water)
(*) for BA 5321D

SERVICE MANUAL
GENERAL INFORMATION
GB
608603992(1)2003-06
S300455
Size in mm
998
560,5
770
1330
1078.5
812
634
1311
998
1078
BA 5321/D
BA 6124D

SERVICE MANUAL
GENERAL INFORMATION
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08603992(1)2003-06 7
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 of 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
Charge the battery •
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 •
Ispezione ai serbatoi e ai tubi
flessibili •
Hose and tank inspection •
Electric suction motor brush (or
carbon brush) check and
replacement •
Electric drive motor brush (or
carbon brush) check and
replacement •
Electric brush rotation motor
brush (or carbon brush) check
and replacement •
Brush rotation toothed belt check •

SERVICE MANUAL
GENERAL INFORMATION
GB
808603992(1)2003-06
MACHINE NOMENCLATURE
In this Manual you find numbers in brackets –example: (2). These numbers refer to the components indicated in
these 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 key switch (*)
3. Brush switch
4. Suction switch
5. Battery condition indicator
6. Detergent flow control lever
7. Hour counter
8. Start/Stop drive panel
9. Squeegee lifting/lowering handle
10. Brush lifting/lowering pedal
11. Water recovery tank
12. Recovery tank automatic float shut-off
13. Suction pre-filter
14. Detergent tank
15. Suction motor
16. Brush motor
17. Traction adjusting handles (BA 5321/D only)
18. Brush (BA 5321/D)
19. Integrated battery charger
20. Circuit panel
21. Drive motor (*)
22. Batteries
23. Squeegee 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. Drive motor thermal fuse
35. Brush motor thermal fuse
36. Suction motor thermal fuse
37. Brush reduction unit (BA 5321/D)
38. Suction cap balancing adjustment handwheel
39. Traction switch (*)
40. Acoustic insulation assembly
41. Brushes (BA 6124D only)
42. Brush motor electronic board and protective cover (BA 6124D
only)
43. Inspection cover for brush rotation belt (BA 6124D only)
44. Brush release push-button (BA 6124D only)
45. Splash-shield (BA 6124D only)
46. Commutator for WET or GEL batteries
47. Electrical connection to the network, during battery recharging
(version with battery charger installed on the machine)
(*) BA 5321D / BA 6124D
S300456

SERVICE MANUAL
GENERAL INFORMATION
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08603992(1)2003-06 9
MACHINE NOMENCLATURE (CONTINUES)
S300163

SERVICE MANUAL
DETERGENT SUPPLY SYSTEM
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10 08603992(1)2003-06
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 right lower side of the machine, close the detergent tap (E). The tap (E) is closed when it is
located at position (F) as to the pipeline; it is open when it is located at position (G).
4. 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).
5. Carry out steps from 1. to 3. in the reverse order.
Figure 1
S300420
REMARK:
The wire gauze (B) must be correctly positioned on the support (C) housing (D).

SERVICE MANUAL
DETERGENT SUPPLY SYSTEM
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08603992(1)2003-06 11
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 supplied key (28) from its housing and unscrew 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 e F4).
12. Disconnect the hoses (F and G).
13. Remove the solenoid valve (D) fastening screws (H).
14. Disconnect the lever (L) control cable (I) of the tap (M). 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
S300421
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
GB
12 08603992(1)2003-06
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

SERVICE MANUAL
DETERGENT SUPPLY SYSTEM
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08603992(1)2003-06 13
TROUBLESHOOTING
SMALL AMOUNT OF THE DETERGENT OR NO DETERGENT REACHES THE BRUSH
Possible cause:
1. The brush switch (3) is not in ON position or it is broken (position it to 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 in the electrical connection (replace the solenoid valve/repair
the electrical connection).
6. The service electronic board is broken (replace it)
7. There is debris in the detergent tank obstructing the output hole (clean the tank).
8. 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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14 08603992(1)2003-06
SWEEPING SYSTEM
BRUSH MOTOR ELECTRICAL INPUT CHECK (BA 5321/D 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 supplied key (28) from its housing and unscrew 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. With an ammeter (C) check that the brush motor input is 8 I 9 A at 24V..
If the electrical input is higher, perform the following operations to detect and correct the causes:
–(AMER motor only) perform the motor brushes check (see the procedure on the following page)
–if necessary, disassemble the motor (see the procedure on the following pages) and check all its parts.
If the above-mentioned procedures do not lead to a correct electrical input, it is necessary to replace the
motor (see the procedure on the following pages).
12. Carry out steps from 1. to 9. in the reverse order.
WARNING!
This procedure must be performed by qualified personnel only.
REMARK:
the motor installed on the machine can either be a BOSCH (shown in the figure below) or a AMER;
the following procedure refers to both types of motors, unless otherwise specified.
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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08603992(1)2003-06 15
BRUSH MOTOR ELECTRICAL INPUT CHECK (BA 6124D Only)
1. Remove the brushes (41).
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 supplied key (28) from its housing and unscrew 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. Unscrew the nuts (A) and remove the brush motor cover (B).
10. Disconnect the electrical cables (C) and (D) connecting the motor (H) to the electronic board (E).
11. Connect the brush motor to the machine battery, as described in the underlying diagram, inserting the 30 A
fuse (F), for safety’s sake.
12. With an ammeter (G) check that the brush motor input is 5 A at 24V max.
If the electrical input is higher, perform the following operations to detect and correct the causes:
–check if foreign matters (debris, cords, etc.) prevent or slow down the brush-holding hubs (41) rotation.
–if necessary, through the cover compartment (43), check that the brush rotation belt is not overtightened
(see the procedure "Brush belt check")
–if necessary, disassemble the motor (see the procedure on the following pages) and check all its 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).
13. Carry out steps from 1. to 10. in the reverse order.
WARNING !
This procedure must be performed by qualified personnel only.
Pay attention to the brush-holding hubs (41) rotation while performing the following steps.

SERVICE MANUAL
SWEEPING SYSTEM
GB
16 08603992(1)2003-06
BRUSH MOTOR ELECTRICAL INPUT CHECK (BA 6124D Only) (Continues)
Figure 3
S300457
Figure 4
S300423
G
F
30A

SERVICE MANUAL
SWEEPING SYSTEM
GB
08603992(1)2003-06 17
BRUSH MOTOR REPLACEMENT (BA 5321/D 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 supplied key (28) from its housing and unscrew 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.
REMARK:
the motor installed on the machine can either be a BOSCH or a AMER.
The following procedure refers to the BOSCH motor only.
CAUTION!
When reinstalling, take care to assemble the bearing (H) with the smaller side (M) facing the
pinion (as shown in the figure).
Figure 5
S300170
Figure 6
S300171

SERVICE MANUAL
SWEEPING SYSTEM
GB
18 08603992(1)2003-06
BRUSH MOTOR REPLACEMENT (BA 5321/D 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 supplied key (28) from its housing and unscrew 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. Unscrew the nuts (D).
12. Carefully lift and remove the brush motor (E) with its pinion and bearing.
13. Install in the reverse order of removal, with the following change:
–if applied at step 12, remember to remove the adhesive tape.
Figure 7
S300424
REMARK:
the motor installed on the machine can either be a BOSCH or a AMER.
The following procedure refers to the AMER motor only.
CAUTION!
To prevent part (F) and part (G) from separating during the motor disassembly/reassembly, it is
advisable to apply adhesive tape temporarily to keep the two parts together.