Nilfisk-Advance BA 1000 Service Manual
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Summary of Contents for Nilfisk-Advance BA 1000
- Page 1 ™ Convertamatic 28/32/38LX ™ Hydro-Retriever 280/320/380HD BA 700/800/1000 SERVICE MANUAL Advance MODELS 56392290, 56392210, 56392220, 56392230, 56392240, 56392270 Nilfisk MODELS 56391372, 56392823, 56392824 9/95 revised 3/01 Form Number 56043025...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY ....................................4 SPECIFICATIONS & MAINTENANCE ..........................5-8 KNOW YOUR MACHINE ............................... 9-10 SOLUTION SYSTEM ..............................11-18 MAINTENANCE ................................11 FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD ..............11-12 FLOW CONTROL VALVE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD ........... 12 SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD .................. -
Page 3: Safety
This machine is not suitable for picking up hazardous dust. • Do not use scarifier discs and grinding stones. Nilfisk-Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones (can also cause damage to the brush drive system). -
Page 4: Specifications & Maintenance
SPECIFICATIONS _________________________________________________________________________________________________________________ SPECIFICATIONS - BA 700 / 28LX / 280HD Dimensions English (Metric) Scrub Brush Diameter 14.5 inches (36 cm) Scrub Brush Path 28 inches (71 cm) Scrub Brush Pressure 140 lbs. (63.5 kg) Scrub Brush Speed 155 rpm (155 rpm) Squeegee Size 33 inches (108 cm) Machine Length... - Page 5 SPECIFICATIONS _________________________________________________________________________________________________________________ SPECIFICATIONS - BA 800 / 32LX / 320HD Dimensions English (Metric) Scrub Brush Diameter 17 inches (43 cm) Scrub Brush Path 32 inches (81 cm) Scrub Brush Pressure 160 lbs. (72.5 kg) Scrub Brush Speed 120 rpm (120 rpm) Squeegee Size 45 inches (114 cm) Machine Length...
- Page 6 SPECIFICATIONS ______________________________________________________________________________________________ SPECIFICATIONS - BA 1000 / 38LX / 380HD Dimensions English (Metric) Scrub Brush Diameter 20 inches (50 cm) Scrub Brush Path 38 inches (97 cm) Scrub Brush Pressure 160 lbs. (72.5 kg) Scrub Brush Speed 120 rpm (120 rpm)
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Page 7: Maintenance Schedule
Check battery water level Lubrication *Vacuum motor carbon brushes *Have your Nilfisk-Advance Dealer check the motors’ carbon brushes once a year or after 300 operating hours. _________________________________________________________________________________________________________________ AFTER EACH USE Raise the brushes (or pads) and raise the squeegee. Move the machine to a service area. -
Page 8: Know Your Machine
KNOW YOUR MACHINE _________________________________________________________________________________________________________________ As you read this manual, you will occasionally run across a bold number in parentheses - example: (2). These numbers refer to an item on this or the following page. Refer back to these pages whenever necessary to pinpoint the location of an item mentioned in the text. Circuit Breaker (5 Amp) Solution Lever Twist Grip... -
Page 9: Know Your Machine
KNOW YOUR MACHINE CONTROL PANEL Battery Meter Brush Switch Solution ON Light Solution Switch, ON - Momentarily ON – OFF Power ON Light 10 - FORM NO. 56043025 / BA 700, 800, 1000 / 28LX, 32LX, 38LX / 280HD, 320HD, 380HD... -
Page 10: Solution System
SOLUTION SYSTEM _________________________________________________________________________________________________________________ MAINTENANCE The solution system should be flushed every day to prevent a build-up of soap residue in the solution valve. To flush the system... Park the machine near a designated “DISPOSAL SITE” and drain the solution tank. Put clean, warm water into the solution tank and let it drain through the drain hose. -
Page 11: Flow Control Valve Replacement - Ba 800, 1000 / 32, 38Lx / 320, 380Hd
SOLUTION SYSTEM _____________________________________________________________________________________________________________________________ FLOW CONTROL VALVE REPLACEMENT - BA 700 / 28LX / 280HD (continued) Follow steps 1 - 5 in reverse order to reassemble. Make sure that the valve mount is in the forward two holes as shown. Check for leaks and proper operation. ______________________________________________________________________________________________ FLOW CONTROL VALVE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD Drain the solution tank at a designated “DISPOSAL SITE”. -
Page 12: Solution Cable Replacement - Ba 700 / 28Lx / 280Hd
SOLUTION SYSTEM ______________________________________________________________________________________________ SOLUTION CABLE REPLACEMENT - BA 700 / 28LX / 280HD FIGURE 3 Drain the solution tank at a designated “DISPOSAL SITE”. See Figure 3. Disconnect Ball Joint (I) from the valve arm. Be careful not to lose the bushings. Remove Ball Joint (I) from the cable, then remove the cable from the chassis cable mount, (note the cable position in... -
Page 13: Solution Cable Replacement - Ba 800, 1000 / 32, 38Lx / 320, 380Hd
SOLUTION SYSTEM ______________________________________________________________________________________________ SOLUTION CABLE REPLACEMENT - BA 800, 1000 / 32, 38LX / 320, 380HD Drain the solution tank at a designated “DISPOSAL SITE”. Remove the left splash guard. FIGURE 5 See Figure 5. Disconnect Ball Joint (L) from the valve arm. Be careful not to lose the bushings. Remove the cable from the chassis cable mount (note the cable position in the mount), then remove Ball Joint (L) from the cable. -
Page 14: Solution Solenoid Valve Removal - Ba 700 / 28Lx / 280Hd
SOLUTION SYSTEM ______________________________________________________________________________________________ SOLUTION SOLENOID VALVE REMOVAL - BA 700 / 28LX / 280HD FIGURE 6 Drain the solution and recovery tanks at a designated “DISPOSAL SITE” and disconnect one of the battery cables. Tip the solution tank over to the side of the machine. -
Page 15: Solution Solenoid Valve Removal - Ba 800, 1000 / 32, 38Lx / 320, 380Hd
SOLUTION SYSTEM ______________________________________________________________________________________________ SOLUTION SOLENOID VALVE REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD FIGURE 8 Drain the solution and recovery tanks at a designated “DISPOSAL SITE” and disconnect one of the battery cables. Tip the solution tank over to the side of the machine. -
Page 16: Solution Solenoid Valve Disassembly And Cleaning
SOLUTION SYSTEM ______________________________________________________________________________________________ SOLUTION SOLENOID VALVE DISASSEMBLY AND CLEANING Remove the solenoid valve (do not remove the fittings from the solenoid valve unless you are replacing the valve!). Refer to the Solution Solenoid Valve Removal sections of this chapter. See Figure 10. Remove the (2) (KK) Screws and Nuts and disassemble the valve (be careful not to lose any internal parts). -
Page 17: Troubleshooting
SOLUTION SYSTEM ______________________________________________________________________________________________ TROUBLESHOOTING ______________________________________________________________________________________________ PROBLEM: NO SOLUTION FLOW Possible Cause & Remedy: Machine controls not positioned properly - in order for solution to flow, the controls must be positioned as follows: • Key Switch - ON • Solution Switch - ON •... -
Page 18: Brush Drive System
BRUSH DRIVE SYSTEM _____________________________________________________________________________ MAINTENANCE Every 3 years... Check the carbon brushes in the brush motor. Replace the brushes if they are worn to a length of 3/8 inch (10 mm) or less. Remove the fill plug from the top of the gear box and check the oil level. The oil should be 1-1/2 inches (3.8 cm) from the top of the gear box. -
Page 19: Belt Tension Adjustment - Ba 800, 1000 / 32, 38Lx / 320, 380Hd
3-1/4 pounds of pressure is applied between the pulleys. After the adjustment is complete, test to make sure the belt does not slip. BA 800 / 32LX / 320HD BA 1000 / 38LX / 380HD FIGURE 2 FRONT FRONT 20 - FORM NO. -
Page 20: Brush Lift Limit Switches
BRUSH DRIVE SYSTEM _____________________________________________________________________________ BRUSH LIFT ACTUATOR LIMIT SWITCHES _____________________________________________________________________________ LIMIT SWITCH ADJUSTMENT Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks under the brush holders and lower the jack enough to take the weight of the brush drive assembly off the actuator. Drain and tip the solution tank to the side of the machine. - Page 21 BRUSH DRIVE SYSTEM _____________________________________________________________________________________________________________________________ LIMIT SWITCH ADJUSTMENT (continued) See Figure 4. Measure the position of the plastic nut on the actuator shaft. Manually turn the plastic nut to the DOWN position given below. FIGURE 4 Plastic Nut Adjuster Cover Down Machine DOWN Position UP Position...
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Page 22: Limit Switch Replacement
BRUSH DRIVE SYSTEM _____________________________________________________________________________________________________________________________ BRUSH LIFT LIMIT SWITCHES (continued) _____________________________________________________________________________ LIMIT SWITCH REPLACEMENT Remove the actuator from the machine (see the Brush Lift Actuator Replacement section). See Figure 5. Remove the (J) Screws and Cover (K), be careful not to lose the spring and washers. Note the position of the Adjuster (L) for reassembly. -
Page 23: Brush Lift Actuator Replacement
BRUSH DRIVE SYSTEM ______________________________________________________________________________________________ BRUSH LIFT ACTUATOR REPLACEMENT Remove the brushes, lower the brush drive and jack up the front of the machine about 2 inches. Put wood blocks under the brush holders and lower the jack enough to take the weight of the brush drive assembly off of the actuator. Drain and tip the solution tank to the side of the machine, and disconnect the batteries. -
Page 24: Troubleshooting
FIGURE 7A BA 700 Before SN 1082069 BA 700 After SN 1082068 Drive Motor Drive Motor BA 800, BA 1000 Before SN 1081111 BA 800, BA 1000 After SN 1081110 Solenoid Solenoid All 28LX / 280HD All 32LX, 38LX / 320HD, 380HD... -
Page 25: Vacuum System
VACUUM SYSTEM ______________________________________________________________________________________________ MAINTENANCE Whenever the vacuum system does not perform properly, the entire system should be cleaned and inspected, following the maintenance checklist below. Remove the squeegee from the machine and clean it thoroughly. Inspect 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. -
Page 26: Vacuum System Maintenance
VACUUM SYSTEM _____________________________________________________________________________________________________________________________ MAINTENANCE (continued) CAUTION! Do not flush hose (C) unless it is disconnected from the vacuum motor. Remove Cover (B) from the recovery tank (see Figure 1). Rinse all dirt from Cage (E) and the ball float inside. Check the gasket on recovery tank Cover (B). -
Page 27: Vacuum Motor Removal - Ba 800, 1000 / 32, 38Lx / 320, 380Hd
VACUUM SYSTEM ______________________________________________________________________________________________ VACUUM MOTOR REMOVAL - BA 800, 1000 / 32, 38LX / 320, 380HD FIGURE 5 Disconnect one of the battery cables. Drain the solution tank and tip it to the side of the machine. See Figure 4. Remove the (4) (I) Screws and remove Cover (J) from the machine. -
Page 28: Squeegee Maintenance
VACUUM SYSTEM ______________________________________________________________________________________________ SQUEEGEE MAINTENANCE If the squeegee leaves narrow streaks of water, the blades may be dirty or damaged. Remove the squeegee, rinse it under warm water and inspect the squeegee blades. Reverse or replace the blades if they are cut, torn, wavy or worn. To Reverse or Replace the Rear Squeegee Wiping Blade... -
Page 29: Squeegee Adjustment (After Sn 1081110)
VACUUM SYSTEM ______________________________________________________________________________________________ SQUEEGEE ADJUSTMENT (BA 700 AFTER SN 1082068 & BA 800/1000 AFTER SN 1081110) ALL 28, 32, 38LX / 280, 320, 380HD Park the machine on a flat, even surface. Lower the squeegee. Loosen the (horizontal) squeegee-mount lock bolt (found on right side next to the recovery hose tube). Loosen the locking nut on the (vertical) tilt adjustment bolt on the squeegee tongue. -
Page 30: Troubleshooting
VACUUM SYSTEM ______________________________________________________________________________________________ TROUBLESHOOTING ______________________________________________________________________________________________ Problem: Machine will not pick up water, water flows around ends of squeegee Possible Cause & Remedy: Plug for recovery tank drain hose not sealing air-tight — install plug properly or replace if damaged. Recovery tank cover not installed properly — push cover down all the way, so it seals air-tight against the top of the tank. - Page 31 Defective vacuum motor — remove motor, repair or replace. Defective vacuum motor solenoid (see Figures 8A and 8B)— replace solenoid. FIGURE 8A BA 700 Before SN 1082069 BA 800, BA 1000 Before SN 1081111 FIGURE 9 FRONT Vac Motor Solenoid...
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Page 32: Wheel Drive System
WHEEL DRIVE SYSTEM ______________________________________________________________________________________________ MAINTENANCE Lubricate the drive wheel bearings once per month. For access to the grease fitting, open the left splash guard, raise the brushes and remove the left scrub brush from the machine. ______________________________________________________________________________________________ CHAIN REMOVAL OR ADJUSTMENT ______________________________________________________________________________________________ CHAIN REMOVAL: Drain and remove the solution and recovery tanks, disconnect and remove the batteries and squeegee. -
Page 33: Drive Motor Replacement
WHEEL DRIVE SYSTEM _____________________________________________________________________________________________________________________________ CHAIN REMOVAL OR ADJUSTMENT (continued) ______________________________________________________________________________________________ CHAIN ADJUSTMENT: Follow steps 1 & 2 from the Chain Removal section above. See Figure 1. Loosen Lock Nut (A), turn Bolt (B) to adjust chain tension. There should be about 1/2 inch (12 mm) of deflection between the sprockets when moderate pressure is applied to the chain. -
Page 34: Drive Wheel Replacement
WHEEL DRIVE SYSTEM ______________________________________________________________________________________________ DRIVE WHEEL REPLACEMENT Drain and remove the solution and recovery tank, disconnect and remove the batteries and squeegee. Remove the left splash guard and scrub brush. Then tip the machine over on its left side. See Figure 2. Loosen Lock Nut (H) and back out Bolt (I) several turns to loosen the tension on the drive chain, then remove the chain from the motor sprocket. -
Page 35: Troubleshooting
WHEEL DRIVE SYSTEM ______________________________________________________________________________________________ TROUBLESHOOTING ______________________________________________________________________________________________ Problem: No wheel drive - forward or reverse Possible Cause & Remedy: Tripped wheel drive circuit breaker - press reset button and check circuit breaker for continuity. Defective wheel drive motor - follow instructions below to test. •... -
Page 36: Potentiometer Adjustment
WHEEL DRIVE SYSTEM ______________________________________________________________________________________________ POTENTIOMETER ADJUSTMENT Adjust the potentiometer if the machine has no drive, or if it moves with the twist grips in neutral. To adjust the potentiometer... Remove the back panel from the control handle. Carefully inspect the potentiometer belt and pulley mechanism for a mechanical defect, correct defects before proceeding. -
Page 37: Battery System
BATTERY SYSTEM ______________________________________________________________________________________________ WARNING! Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact skin or eyes. Explosive hydrogen gas is vented from inside the batteries through openings in the battery caps. This gas can be ignited by any electrical arc, spark or flame. -
Page 38: Battery Testing
BATTERY SYSTEM ______________________________________________________________________________________________ BATTERY TESTING A battery problem is usually recognized by the machine operator, as a decrease in the machine’s running time. This condition is usually caused by one (or more) “dead cell” in the battery system- that is, one (or more) cell that is putting out less voltage than the other cells. - Page 39 NOTES 40 - FORM NO. 56043025 / BA 700, 800, 1000 / 28LX, 32LX, 38LX / 280HD, 320HD, 380HD...
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Page 40: Electrical System
ELECTRICAL SYSTEM COMPONENT LOCATION Item Description Speed Controller Actuator Control Module Circuit Breaker 5 Amp (Control Circuit) Circuit Breaker 25 Amp (Wheel Drive) Circuit Breaker 25 Amp (Vacuum Motor) Circuit Breaker 80 Amp (Brush Motor) Solenoid (Vac Motor) Solenoid (Brush Motor) Solenoid (Wheel Drive Motor) Solution Solenoid Valve Vacuum Motor... - Page 41 ELECTRICAL SYSTEM BA 700 Before SN 1082069 BA 800, BA 1000 Before SN 1081111 36 Vdc VIO/BRN BLU/WHT VIO/BRN BRN/RED GRN/BLU WHT/RED BRN/WHT DOWN YEL/WHT WHT/BLK YEL/VIO WHT/ORN WHT/GRN RED/GRN FWD. OFF REV. RED/BLK ORN/BLK YEL/BRN YEL/BLK 42 - FORM NO. 56043025 / BA 700, 800, 1000 / 28LX, 32LX, 38LX / 280HD, 320HD, 380HD...
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Page 42: Wiring Diagrams / Schematics
ELECTRICAL SYSTEM WIRING DIAGRAM / SCHEMATIC BA 700’s Before SN 1082069 BA 800/1000 Before SN 1081111 Item Description Speed Controller Batteries Suppression Diode BLK 0J-B BLK 0A-B Suppression Diode BLK 0L-B Suppression Diode BRN 1A-A Suppression Diode VIO 7D-B Regenerative Feedback Diode RED 2D-B BLU 6A-A Time Delay Module (on break) - Page 43 ELECTRICAL SYSTEM • Convertamatic 28/32/38LX Before SN 1082119 • Hydro Retriever 280/320/380HD Before SN 1082119 • BA 700 between SN 1082069 and SN 1082119 • BA 800, BA 1000 between SN 1081111 and SN 1082119 36 Vdc VIO/BRN BLU/WHT VIO/BRN...
- Page 44 ELECTRICAL SYSTEM WIRING DIAGRAM / SCHEMATIC •Convertamatic 28/32/38LX Before SN 1082119 •Hydro Retriever 280/320/380HD Before SN 1082119 •BA 700 between SN 1082069 and SN 1082119 •BA 800, BA 1000 between SN 1081111 and SN 1082119 Item Description Speed Controller BLK 0A-B...
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Page 45: Electrical System
ELECTRICAL SYSTEM All Models After SN 1082118 36 Vdc VIO/BRN BLU/WHT VIO/BRN BRN/RED IN 2 RED/GRN IN 1 BLK/YEL TIMER OUT WHT/RED ORN/BLK MOTOR - RED/BLK MOTOR + DOWN RED/WHT YEL/WHT RED/WHT WHT/ORN WHT/GRN GRN/BLU GRN/BLU FWD. OFF REV. YEL/BRN YEL/BLK 46 - FORM NO. - Page 46 ELECTRICAL SYSTEM WIRING DIAGRAM / SCHEMATIC All Models After SN 1082118 Item Description Speed Controller Batteries Suppression Diode BLK 0C-A BLK 0L-B Suppression Diode BLK 0B-A Suppression Diode VIO 7J-B BRN 1A-B Regenerative Feedback Diode VIO 7K-B RED/WHT 29A-A Actuator Control Module BLU 6A-A 5 Amp Circuit Breaker WHT/GRN 95A-B...
- Page 47 ¤ +1 800 989 2235 – Fax 1 800 989 6566 Dublin 18 ¤ +353 1 2943838 – Fax +353 1 2943845 SVERIGE Nilfisk-Advance AB Nilfisk-Advance of America, Inc. Sjöbjörnsvägen 5, 117 67 Stockholm JAPAN 300 Technology Drive ¤ 085 55 944 00 – Fax 085 55 944 30 Nilfisk-Advance Inc.