Nilfisk-Advance BA 500 User manual

Model 66324400 12/94 Form Number 043023
NILFISK BA 500
Service Manual
ORDER PARTS
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Phone: [phone]

TABLE OF CONTENTS
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Batteries .................................................................................................................21
Brush Drive Belt Adjustme t Or Replaceme t .........................................................7
Brush Drive Motor - Carbo brush I spectio ......................................................... 8
Brush Drive Motor Replaceme t ............................................................................. 8
Brush Drive System Mai te a ce ............................................................................7
Brush Drive System Troubleshooti g .....................................................................10
Differe tial Replaceme t ........................................................................................16
Pote tiometer Adjustme t ......................................................................................20
Safety .......................................................................................................................1
Sole oid Valve - Removal / Disassembly & Clea i g ..............................................4
Solutio System Mai te a ce..................................................................................4
Solutio System Troubleshooti g.............................................................................6
Specificatio s & Mai te a ce ..................................................................................2
Squeegee Adjustme t ............................................................................................13
Vacuum Motor Removal .........................................................................................12
Vacuum System Mai te a ce................................................................................11
Vacuum System Troubleshooti g...........................................................................14
Wheel Drive Chai - Replaceme t Or Adjustme t .................................................17
Wheel Drive Motor Replaceme t ...........................................................................17
Wheel Drive System Troubleshooti g ....................................................................18
Note: All refere ces to right, left, fro t, or rear i this ma ual are as see from the operator’s sta d-poi t.

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SYMBOLS
Nilfisk uses the symbols below to sig al pote tially da gerous co ditio s. Always read this i formatio
carefully a d take the ecessary steps to protect perso el a d property.
DANGER!
Is used to war of immediate hazards that will cause severe perso al i jury or death.
WARNING!
Is used to call atte tio to a situatio that could cause severe perso al i jury.
CAUTION!
Is used to call atte tio to a situatio that could cause mi or perso al i jury or damage to the machi e or other
property.
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GENERAL SAFETY INSTRUCTIONS
WARNING!
Keep sparks, flame a d smoki g materials away from the batteries. Explosive gases are ve ted duri g
ormal operatio .
Remove all jewelry whe worki g ear electrical compo e ts.
Disco ect o e of the battery termi als whe servici g electrical compo e ts.
Never work u der a machi e without safety sta ds or blocks to support the machi e.
CAUTION!
Carefully read all i structio s pertai i g to a service fu ctio before performi g that fu ctio .
Take precautio s to preve t hair, jewelry, or loose clothi g from becomi g caught i movi g parts.
SAFETY
1 BA 500 Service Ma ual

SPECIFICATIONS
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SPECIFICATIONS
Dimensions English (Metric)
Scrub Brush Diameter 20 inches (51 cm)
Scrub Brush Path 20 inches (51 cm)
Scrub Brush Pressure 70 lbs (32 kg)
Scrub Brush Speed 190 rpm (190 rpm)
S ueegee Size 25.5 inches (65 cm)
Machine Length 44 inches (112 cm)
Machine Width 21.75 inches (55 cm)
Machine Height 43.5 inches (110 cm)
Drive Wheel 8 inch (20 cm) soft ride wheels
Solution Tank Capacity 12 gal (45i)
Recovery Tank Capacity 12 gal (45i)
Coverage Rate 7,500 s ft (697 m2) per hour
Machine Weight 266 lbs (121 kg) net w/o batteries
558 lbs (253 kg) w/four 244 AH batteries
376 lbs (175 kg) w/two 93 AH batteries
350 lbs (159 kg) shipping weight
General Speci ications
Brush Motor 24 volt, 1/2 hp dc motor
Wheel Drive Motor 24 volt, 1/4 hp dc motor
Vacuum Motor 24 volt, 3/4 hp dc motor
Brush Drive Belt drive
Sound Level 68.2 db (A) @ 3 ft (.9m) using pads
68.9 db (A) using prolene scrub brushes
S ueegee Type 4 sided, curved, pivot type
Speed Control Electronic, fully variable forward/reverse
Batteries (4) 6 volt 244 AH (std)
(2) 12 volt 93 AH (opt)
BA 500 Service Manual 2

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MAINTENANCE CHART
Once a Once a Once a
MAINTENANCE ITEM Daily Week Month Year
Clean and inspect the tanks and hoses X
Clean the brushes and pads X
Clean the s ueegee X
Charge the batteries X
Check battery water level X
Lubrication X
Vacuum motor carbon brushes X
MAINTENANCE
3 BA 500 Service Manual
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SOLUTION SYSTEM
1Remove the vacuum motor. See
Vacuum System chapter for instruc-
tions.
2Disconnect the solution valve and
mercury switch wiring connectors.
3See Figure 1. Remove hoses “A” and
“ ”.
4Remove (2) bolts “C” and remove the
solution valve and bracket from the
machine.
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MAINTENANCE
The solution system should be thoroughly flushed once a week. To flush the solution system...
1Empty the solution tank, using the clear plastic drain hose on back of machine. This automatically
flushes loose dirt from solution filter.
2Put clean, warm water into the solution tank and let it drain through the drain hose.
3Put the plug in the drain hose and put about 2 inches of clean water in the solution tank.
4Put the machine controls in the following positions:
• Key Switch - ON
• Solution Switch (on left side of handle) - ON
• rush drive lowered
• Twist Grips - Forward
• Flow control lever (on right side of control handle) UP
• Let all of the clean water flow from the tank. This will flush dirt and soap residue from the electric sole-
noid valve and the flow control valve.
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SOLENOID VALVE REMOVAL
C
A
FIGURE 1
Front
BA 500 Service Manual 4

SOLUTION SYSTEM
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SOLENOID VALVE DISASSEMBLY AND CLEANING
1Remove the solenoid valve. See the Solenoid Valve Removal section for instructions.
2See Figure 2. Remove the (2) “D” screws and nuts and disassemble the valve (be careful not to lose any
internal parts).
3Thoroughly wash dirt from block “E” and diaphram “F”.
4After reassembling, test the solenoid valve for proper operation.
D
D
FIGURE 2
EF
5 BA 500 Service Manual

SOLUTION SYSTEM
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TROUBLESHOOTING
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Probl m: No solution flow
Possibl Caus and R m dy:
1Machine controls not positioned properly. In order for solution to flow, the controls must be positioned as
follows:
• Key Switch - ON
• Solution Switch (on left side of handle) - ON
• rush drive lowered
• Twist Grips - Forward
• Flow control lever (on right side of control handle) UP
2Clogged Solution Filter. Drain solution tank, using the clear plastic drain hose on back of machine. This
automatically flushes loose dirt from solution filter. If solution still does not flow, remove and disassemble
the tee-fitting (under the solution tank), remove and clean the filter thoroughly.
3Clogged Solenoid Valve. Remove, disassemble, and clean the solenoid valve. See the Solenoid Valve
Disassembly and Cleaning section for instructions.
4Defective Speed Control. Replace speed control.
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Probl m: Solution leaks in “OFF” position
Possibl Caus and R m dy:
1Dirt in solenoid valve. Remove, disassemble, and clean the solenoid valve. See the Solenoid Valve
Disassembly and Cleaning section for instructions.
2Defective solenoid valve. Replace the solenoid valve. See the Solenoid Valve Removal section for
instructions.
BA 500 Service Manual 6

BRUSH DRIVE SYSTEM
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MAINTENANCE
Once every six months
1Check the belt tension, adjust if necessary.
Once a year
1Check the carbon brushes in the brush motor. Replace the brushes if they are worn to a length of 3/8
inch ( 0 mm) or less.
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BELT ADJUSTMENT OR REPLACEMENT
1Drain the solution and recovery tanks.
2See Figure . Tip the machine back as
shown and place a jack stand under the
front end.
3See Figure 2. Turn nut “A” counterclockwise to loosen the belt tension.
FIGURE 1
FIGURE 2
4Remove screw “B” and remove the idler assembly and the belt from the machine. Remove “E” bolts, and
remove the belt from the idler.
5Follow steps in reverse order to reassemble. Tighten nut “A” until the tension spring is 2 /2 inches (63.5
mm) long. Test the brush drive system to make sure it operates properly.
AD
E
C
D
C
B
Front
7 BA 500 Service Manual

BRUSH DRIVE SYSTEM
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BRUSH DRIVE MOTOR - CARBON BRUSH INSPECTION
1Remove the brush drive motor. See the Brush Drive Motor Replacement section for instructions.
2See Figure 3. Place the brush drive motor in a vice as shown. Be careful not to damage the pulley.
FIGURE 4FIGURE 3
3See Figure 4. Remove (2) “F” nuts and remove the end bell from the motor.
4Remove and measure the carbon brushes. If they are worn to 3/8 inch (9.66 mm) or shorter, replace
both carbon brushes. Remove all loose carbon and dirt from the inside of the motor.
5Follow steps -3 in reverse order to reassemble.
6Test the motor to make sure it operates properly.
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BRUSH DRIVE MOTOR REPLACEMENT
1Drain the solution and recovery tanks and remove the solution tank from the machine.
2Tip the recovery tank to the side and disconnect the batteries.
3Remove the vacuum motor. See the Vacuum System section for instructions.
4Disconnect the wires from the brush drive motor. Take note of which wire color goes to each terminal for
reassembly.
FF
BA 500 Service Manual 8

BRUSH DRIVE SYSTEM
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BRUSH DRIVE MOTOR REPLACEMENT, (continued)
5See Figure 5. Tip the machine back as
shown and place a jack stand under the
front end.
FIGURE 5
FIGURE 6
7Remove screw “H”, the idler assembly and the belt from the machine.
8Remove (2) “I” bolts and (2) “J” nuts. Set the front of the machine back on the floor and pull the brush
drive motor up and out of the machine.
9Remove the pulley from the old motor and install it on the new one.
10 Follow steps -7 in reverse order to reassemble. Tighten nut “G” until the tensioning spring is 2 /2
inches (63.5 mm) long.
11 Test the brush drive system.
GJI
K
J
I
H
Front
6See Figure 6. Turn nut “G” counterclockwise to loosen the belt tension.
9 BA 500 Service Manual

BRUSH DRIVE SYSTEM
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TROUBLESHOOTING
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Problem: Squealing noise when brush is lowered.
Possible Cause and Remedy:
1Loose belt — adjust belt tension.
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Problem: Brush motor will not start when twist grips are turned.
Possible Cause and Remedy:
1Tripped brush motor circuit breaker (see
Figure 7) — press the reset button, check
circuit breaker for continuity.
2Defective brush motor solenoid (see
Figure 7) — replace solenoid.
3Defective brush motor switch (see Figure
7) — replace switch.
4Defective brush motor — remove motor,
repair or replace.
5Defective speed control or potentiometer
— replace speed control or potentiometer.
FIGURE 7
Brush
Drive
Circuit
Breaker
Front
Brush Motor Switch
Brush Drive
Solenoid
BA 500 Service Manual 10

VACUUM SYSTEM
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MAINTENANCE
FIGURE 1
Whenever the vacuum system does not perform
properly, the entire system should be cleaned and
inspected, following the maintenance checklist
below.
1Remove the squeegee from the machine and
clean it thoroughly.
2Inspect the squeegee blades. If the wiping
edge of the rear blade is damaged or worn to
a radius, turn it around or over so a new
edge with a sharp corner faces toward the
front of the machine.
3See Figure . Disconnect squeegee hose
“A” from left side of recovery tank cover “B”.
Park the machine outside or near a floor
drain and use a garden hose to “back flush”
dirt down and out of squeegee hose “A”.
CAUTION!
Do not flush hose “C” unless it is disconnected
from the vacuum motor.
4Remove cover “B” from the recovery tank
(see Figure ). Rinse all dirt from cage “E”
and ball “F”.
5Check the gasket on recovery tank cover “B”.
It must seal air-tight against the top of the
tank.
B
C
A
Front
E
F
6Check drain hose cap “D”. Replace the cap if it does not seal air-tight.
If the machine still does not pick up after completing this checklist, see the Troubleshooting section of this
chapter for additional information.
11 BA 500 Service Manual
D

VACUUM SYSTEM
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VACUUM MOTOR REMOVA
1Drain the recovery tank, and tip it to the side of
the machine.
2Drain the solution tank, disconnect the hose
from the bottom of the tank and remove the
tank from the machine.
3Disconnect one of the battery cables.
4See Figure 2. Remove the (4) “G” screws and
lift cover “H off of the machine, along with
FIGURE 2
bracket “I”.
5See Figure 3. Remove the (4) “J” screws.
6Disconnect the vacuum motor wiring connector.
7Disconnect hose “K” from the vacuum motor assembly and remove the motor from the machine.
FIGURE 3
G
H
G
J
K
Front
BA 500 Service Manual 12
I

VACUUM SYSTEM
FIGURE 4
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SQUEEGEE ADJUSTMENT
1Adjust the large knob “M” on the back of the squeegee mount until both front and rear blades touch the
floor equally.
Front
M
13 BA 500 Service Manual

VACUUM SYSTEM
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TROUB ESHOOTING
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Problem: Machine will not pick up water, water flows around ends of squeegee.
Possible Cause and Remedy:
1Cap for recovery tank drain hose not sealing air-tight — install cap properly or replace if damaged.
2Recovery tank cover not installed properly — push cover down all the way, so it seals air-tight against the
top of the tank.
3Damaged gasket on recovery tank cover — replace gasket.
4Low battery voltage — charge or replace batteries.
5Vacuum motor defective — repair or replace vacuum motor.
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Problem: Water in vacuum motor
Possible Cause and Remedy:
1Operator using high-sudsing detergent — use low-sudsing detergent or add a defoaming chemical to the
recovery tank.
2Vacuum leak in recovery tank drain hose or cap — replace hose or cap.
3Vacuum shut-off float ball not closing — clean or replace float ball and cage (mounted on recovery tank
cover).
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Problem: Float closes before tank is full
Possible Cause and Remedy:
1Foam in recovery tank — advise operator to use low-sudsing detergent or add a defoaming chemical to
the recovery tank.
2Cage around vacuum shut-off float clogged — disconnect hoses from recovery tank cover, remove the
cover and clean or replace the float cage.
BA 500 Service Manual 14

VACUUM SYSTEM
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Problem: Vacuum motor will not run when squeegee is lowered
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TROUB ESHOOTING, (continued)
Possible Cause and Remedy:
1Tripped vacuum motor circuit breaker (see
Figure 5) — press reset button, check circuit
breaker for continuity.
2Defective vacuum switch (see Figure 6) —
remove cover panel from back of control
handle, adjust or replace switch.
3Defective vacuum motor — remove motor,
repair or replace.
4Defective vacuum motor solenoid — replace
solenoid.
Vacuum Motor
Solenoid
Front
Vacuum Motor
Circuit Breaker
FIGURE 5
Vacuum Motor Switch
FIGURE 6
15 BA 500 Service Manual

WHEEL DRIVE SYSTEM
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DIFFERENTIAL REPLACEMENT
1Drain the tanks, remove the batteries and tip the machine up on it’s nose.
2See Figure 1. Remove chain guard "K" (snaps in place . Loosen the chain tensioning bolt “A”.
3Disconnect the master link in the chain and remove the chain. FIGURE 1
4Remove the “B” bolts and remove the wheels.
5Remove the (6 "C" differential mounting bolts and nuts and “D” bushings. Remove the differential from
the machine.
6Remove the sprocket, “E” collars, “F” bearings, and “G” bushings from the old differential and install them
on the new one, (take note of the location of the “E” collars on the axles for reassembly .
7Follow steps 1-5 in reverse order to reassemble. (Refer to the Drive Chain Replacement Or Adjustment
section for proper chain tension .
8Test the drive system for proper operation.
H
K
A
J
F
G
B
Front
I
CD
CE
BA 500 Service Manual 16

WHEEL DRIVE SYSTEM
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DRIVE MOTOR REPLACEMENT
1Drain the tanks, remove the batteries and tip the machine up on it’s nose.
2Disconnect the squeegee lift cable and the squeegee hose.
3See Figure 1. Remove chain guard "K" (snaps in place .
4Loosen lock nut “J” and turn bolt “A’ to loosen the chain tension (On reassembly, refer to the Drive Chain
Adjustment section for proper chain tensioning .
5Disconnect the master link on the chain and remove the chain.
6Disconnect the drive motor from the wiring harness.
7Remove the (2 “I” bolts and nuts and remove the drive motor from the machine.
8Remove the old drive motor from the motor mount and install the new motor on the mount.
9Remove the chain guard “H” from the old motor and install it on the new one.
1 Follow steps 1-6 in reverse order to reassemble.
11 Test the drive system for proper operation.
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DRIVE CHAIN REPLACEMENT OR ADJUSTMENT
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Replacement:
•Refer to steps 1, 3 & 4 of the Drive Motor Replacement section for instructions. Follow these steps in
reverse order to reassemble.
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Adjustment:
•See Figure 1. Loosen the lock nut “J”, turn bolt “A” to tighten or loosen the chain. There should be about
1/2 inch (12 mm of deflection between the sprockets when moderate pressure is applied to the chain.
• After replacing or adjusting the chain, test the drive system for proper operation.
17 BA 500 Service Manual

WHEEL DRIVE SYSTEM
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TROUBLESHOOTING
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Problem: No wheel drive - forward or reverse
Possible Cause & Remedy:
1Tripped wheel drive circuit breaker (see Figure 2 - press reset button, if wheel drive still doesn’t work,
check circuit breaker for continuity.
FIGURE 2
2Defective wheel drive motor - follow instructions below.
•Jack up the rear of the machine to lift the drive wheels off the floor.
•Remove back panel from control handle.
•Remove the plastic cover from the speed control.
•Disconnect the brown/yellow and the white/brown wires from the speed control and connect them to a
battery, using jumper wires.
•If the wheel motor turns, go to step 3. If the wheel motor does not turn, remove the tanks and batteries,
tip the machine up on its nose and repair or replace the wheel drive motor.
Front
Wheel Drive
Circuit Breaker
BA 500 Service Manual 18