Nilfisk-Advance BA 1000, Service Manual

Page 1: ... Form Number 56043025 SERVICE MANUAL Advance MODELS 56392290 56392210 56392220 56392230 56392240 56392270 Nilfisk MODELS 56391372 56392823 56392824 Convertamatic 28 32 38LX Hydro Retriever 280 320 380HD BA 700 800 1000 ...

Page 2: ...ON ADJUSTMENT BA 800 1000 32 38LX 320 380HD 20 BRUSH LIFT LIMIT SWITCHES 21 23 LIMIT SWITCH ADJUSTMENT 21 22 LIMIT SWITCH REPLACEMENT 23 BRUSH LIFT ACTUATOR REPLACEMENT 24 TROUBLESHOOTING 25 VACUUM SYSTEM 26 32 VACUUM SYSTEM MAINTENANCE 26 27 VACUUM MOTOR REMOVAL BA 700 28LX 280HD 27 VACUUM MOTOR REMOVAL BA 800 1000 32 38LX 320 380HD 28 SQUEEGEE MAINTENANCE 29 SQUEEGEE ADJUSTMENT BEFORE SN 1081111...

Page 3: ...ts Never work under a machine without safety blocks or stands to support the machine Donotdispenseflammablecleaningagents operatethemachineonorneartheseagents oroperateinareaswhereflammable liquids exist Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than an 8 7 percent gradient CAUTION This machine is not approved for use on public paths ...

Page 4: ...es 116 cm Drive Wheel 10 inch 25 cm solid traction tire Solution Tank Capacity 33 US gal 125 l Recovery Tank Capacity 31 US gal 118 l Coverage Rate 25 500 sq ft 2 369 m2 per hour Machine Weight 1520 lbs 690 kg Gross Vehicle Weight GVW GVW Standard machine without options maximum size batteries fullsolutiontank emptyrecoverytankandbrushes 770 lbs 349 kg shipping weight General Specifications Brush ...

Page 5: ...eight 46 75 inches 119 cm Drive Wheel 10 inch 25 cm solid traction tire Solution Tank Capacity 33 gal 125 l Recovery Tank Capacity 31 gal 118 l Coverage Rate 32 500 sq ft 3 019 m2 per hour Machine Weight 1 718 lbs 779 kg Gross Vehicle Weight GVW GVW Standard machine without options maximum size batteries fullsolutiontank emptyrecoverytankandbrushes 825 lbs 374 kg shipping weight General Specificat...

Page 6: ...cm Drive Wheel 10 inch 25 cm solid traction tire Solution Tank Capacity 33 gal 125 l Recovery Tank Capacity 31 gal 118 l Coverage Rate 35 000 sq ft 3 251 m2 per hour Machine Weight 1 747 lbs 792 kg Gross Vehicle Weight GVW GVW Standard machine without options maximum size batteries fullsolutiontank emptyrecoverytankandbrushes 878 lbs 398 kg shipping weight General Specifications Brush Motor 36 vol...

Page 7: ...the plug Rinse the tank with clean water Inspect the solution hoses replace if kinked or damaged 4 Toemptytherecoverytank taketheRecoveryDrainHose 12 offitshanger Directthehosetoadesignated DISPOSALSITE and remove the plug Rinse the tank with clean water Inspect the recovery and vacuum hoses replace if kinked or damaged 5 Remove the brushes or pad holders Rinse the brushes or pads with warm water ...

Page 8: ...er 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 1 Solution Lever 2 Twist Grip 3 Solution Tank Cover 4 Brake Lever 5 Power Connector 6 Circuit Breaker 80 Amp 7 Circuit Breaker 25 Amp 8 Circuit Breaker 25 Amp 9 Circuit Breaker 5 Amp 10 Squeegee Lever 11 Mast...

Page 9: ...043025 BA 700 800 1000 28LX 32LX 38LX 280HD 320HD 380HD KNOW YOUR MACHINE CONTROL PANEL 17 Battery Meter 18 Brush Switch 19 Solution ON Light 20 Solution Switch ON Momentarily ON OFF 21 Power ON Light 18 17 21 19 20 ...

Page 10: ...ON Brush Drive 18 Lowered Twist Grips 2 Forward slightly Solution Flow Control Lever 1 Pulled Back 5 Let all of the clean water flow from the tank This will flush dirt and soap residue from the electric solenoid valve and the flow control valve ______________________________________________________________________________________________ FLOW CONTROL VALVE REPLACEMENT BA 700 28LX 280HD 1 Drain the...

Page 11: ...he E F and G Hoses from the solution valve fittings and mark them to ensure proper reassembly 4 RemoveBallJoint H fromthevalve arm Be careful not to lose the bushings 5 Remove the valve mounting bolts and remove the valve from the ma chine 6 Remove the fittings from the old valve and remove the valve from the mount note the positioning of the fittings for reassembly 7 Install the new valve on the ...

Page 12: ...ushings 3 Remove Ball Joint I from the cable then remove the cable from the chassis cable mount note the cable position in the mount 4 See Figure 4 Remove Panel J 5 Disconnect Ball Joint K from the lever and then remove the balljoint from the cable 6 Remove the cable from the control handle cable mount note the cable position in the mount 7 Before removing the cable take note of the cable routing ...

Page 13: ...ble from the chassis cable mount note the cable position in the mount then remove Ball Joint L from the cable 5 See Figure 4 Remove Panel J 6 Disconnect Ball Joint K from the lever and then remove the balljoint from the cable 7 Remove the cable from the control handle cable mount note the cable position in the mount 8 Before removing the cable take note of the cable routing Pull the cable down and...

Page 14: ... the solution tank over to the side of the machine 3 See Figure 6 Remove the 4 M ScrewsandremoveCover N from the machine 4 See Figure 7 Disconnect Hoses O P Q and then disconnect the solenoid valve wiring connec tor FIGURE 6 FIGURE 7 5 Remove the 2 R Screws remove the Solenoid Valve S and Bracket T from the machine 6 Remove the fittings from the solenoid valve only if you are replacing the solenoi...

Page 15: ... 2 Tip the solution tank over to the side of the machine 3 See Figure 8 Remove the 4 Y ScrewsandremoveCover Z from the machine 4 See Figure 9 Disconnect Hoses AA BB CC and then discon nectthesolenoidvalvewiringcon nector 5 Remove the 2 DD Screws remove the Solenoid Valve EE and Bracket FF from the machine 6 Remove the fittings from the solenoid valve only if you are replacing the solenoid valve re...

Page 16: ...NG 1 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 2 See Figure 10 Remove the 2 KK Screws and Nuts and disassemble the valve be careful not to lose any internal parts FIGURE 10 3 Thoroughly wash any dirt from Block LL and Diaphragm MM 4 Reassemble in reverse order...

Page 17: ...the back of the machine This automaticallyflushesloosedirtfromthesolutionfilter Ifsolutionstilldoesnotflow removeanddisassemblethetee fitting attached to the solenoid valve and remove and clean the filter thoroughly 3 Clogged solenoid valve remove disassemble and clean the solenoid valve See the Solenoid Valve Disassembly and Cleaning section for instructions 4 Defective speed control replace the ...

Page 18: ...he oil level The oil should be 1 1 2 inches 3 8 cm from the top of the gear box Use 140W gear lube only 3 Check the belt tension There should be about 3 32 inch 2 mm of belt deflection when 3 1 4 pounds of pressure is applied between the pulleys _____________________________________________________________________________ BELT TENSION ADJUSTMENT BA 700 28LX 280HD 1 Remove the actuator from the mac...

Page 19: ..._____________________________________________ BELT TENSION ADJUSTMENT BA 800 1000 32 38LX 320 380HD 1 Drain and tip the solution tank to the side of the machine 2 See Figure 2 Loosen the E Bolts and Nuts 3 Loosen the lock nuts and turn the F Bolts to adjust the belt tension There should be about 3 32 inch 2 mm of belt deflection when 3 1 4 pounds of pressure is applied between the pulleys 4 After ...

Page 20: ...wer 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 2 Drain and tip the solution tank to the side of the machine 3 See Figure 3 Loosen the 2 G Bolts and Nuts until the plastic nut on the actuator slips out of the brackets 4 Remove Ring H and Pin I li...

Page 21: ...he brush lift switch in the UP position and wait until the actuator stops 8 Measure the position of the plastic nut on the actuator shaft and compare your measurement with the UP position given above 9 RemovetheadjustercoverfromthetopoftheactuatorandadjusttheUPposition Toincreasethetraveloftheplastic nut turn the adjuster clockwise To decrease the travel of the plastic nut turn the adjuster counte...

Page 22: ...gandwashers Notetheposition of the Adjuster L for reassembly 3 Remove the M Diodes from the switches _____________________________________________________________________________________________________________________________ BRUSH LIFT LIMIT SWITCHES continued 4 Remove the N Screws the switches and the switch shroud 5 Follow steps 2 4 in reverse order to reassemble the actuator 6 After reassembl...

Page 23: ...the brush drive assembly off of the actuator 2 Drain and tip the solution tank to the side of the machine and disconnect the batteries 3 See Figure 6 Loosen the 2 O Bolts and Nuts until the plastic nut on the actuator slips out of the brackets do not turn this nut if you are reinstalling the same actuator 4 Unplug the actuator cord Remove Nut P and Bolt Q Remove the actuator from the machine 5 Fol...

Page 24: ..._______________________________________________________________________________________________ Problem Brush motor will not start when twist grips are turned Possible Cause Remedy 1 Tripped brush motor circuit breaker see Figures 7A 7B press the reset button check the circuit breaker for continuity 2 Defective brush switch on top of control handle replace switch 3 Defective brush motor solenoid s...

Page 25: ...ed following the maintenance checklist below 1 Remove the squeegee from the machine and clean it thoroughly 2 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 3 See Figure 1 Disconnect Squeegee Hose A from the recovery tank cover Park the machine near a desi...

Page 26: ...checklist see the Troubleshooting section of this chapter for additional information ______________________________________________________________________________________________ VACUUM MOTOR REMOVAL BA 700 28LX 280HD _____________________________________________________________________________________________________________________________ MAINTENANCE continued 1 Disconnect one of the battery c...

Page 27: ..._ VACUUM MOTOR REMOVAL BA 800 1000 32 38LX 320 380HD 1 Disconnect one of the battery cables 2 Drain the solution tank and tip it to the side of the machine 3 See Figure 4 Remove the 4 I Screws and remove Cover J from the machine 4 See Figure 5 Remove the 3 K Screws and disconnect the vacuum motor wiring connector 4 Remove the vacuum motor from the machine FIGURE 5 I FRONT J FIGURE 4 ...

Page 28: ...following steps 1 3 in reverse order FIGURE 6 To Reverse or Replace the Front Squeegee Blade 1 Put the Squeegee Lever in the UP position and remove the vacuum hose from the squeegee tool 2 Loosen the two thumb screw on top of the squeegee and slide the squeegee tool off of the squeegee mount 3 Remove the nuts that hold the front blade in place then remove the blade 4 The front squeegee blade has 4...

Page 29: ...t even surface 2 Lower the squeegee 3 Loosen the horizontal squeegee mount lock bolt found on right side next to the recovery hose tube 4 Loosen the locking nut on the vertical tilt adjustment bolt on the squeegee tongue 5 Turn the adjustment bolt with a wrench to tilt the tool forward or backwards until the rear squeegee wiping blade touches the floor across its entire width 6 Re tighten both the...

Page 30: ...e batteries 5 Vacuum motor defective repair or replace vacuum motor ______________________________________________________________________________________________ Problem Water in vacuum motor Possible Cause Remedy 1 Operator using high sudsing detergent use low sudsing detergent or add a defoaming chemical to the recovery tank 2 Vacuum leak in recovery tank drain hose or plug replace hose or plug...

Page 31: ...Vacuum motor will not run when squeegee is lowered Possible Cause Remedy 1 Tripped vacuum motor circuit breaker see Figures 8A and 8B press reset button check circuit breaker for continuity 2 Defective vacuum switch see Figure 9 remove cover panel from back of control handle adjust or replace switch 3 Defective vacuum motor remove motor repair or replace 4 Defective vacuum motor solenoid see Figur...

Page 32: ... ______________________________________________________________________________________________ CHAIN REMOVAL 1 Drain and remove the solution and recovery tanks disconnect and remove the batteries and squeegee 2 Remove the left splash guard and scrub brush Then tip the machine over on its left side 3 See Figure 1 Loosen Lock Nut A and back out Bolt B several turns to loosen tension on the drive ch...

Page 33: ...n tip the machine over on its left side 3 SeeFigure1 CuttheplastictiestrapholdingthevachoseandwiringontomotormountBracket C Thendisconnect the 2 motorwiresfromtheredterminals Notethatthepositivemotorwireandthebluewirefromthemachinewiring harness are connected to the same terminal 4 Remove the Bolt D and Washer E from the end of the motor shaft 5 Loosen Lock Nut A and back out Bolt B several turns ...

Page 34: ...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 4 Remove the 4 J Bolts 2 at each end of the axle and pull the wheel assembly away from the machine frame 5 Remove the 6 bolts that hold the brake disc and sprocket on the wheel 6 Using a rubber mallet or brass drift drive the axle and one of the bearings out of...

Page 35: ...move the tanks and batteries tip the machine on its side and repair or replace the wheel drive motor 3 Defect in potentiometer mechanism follow instructions below to test Make sure that the white green and black wires are firmly connected to the potentiometer The white wire should be on the potentiometer terminal closest to the front of the machine the green wire on the center terminal and the bla...

Page 36: ...h the green black and white wires off of the speed control 4 Connect an ohmmeter on 0 x 100 scale to the green and white wires on the connector The meter should read between 2400 and 2600 ohms If it does not go to the next step 5 Loosen the 2 set screws using a 5 64 Allen wrench in the potentiometer pulley and slide it off of the potentiometer shaft if the potentiometer shaft does not have a slot ...

Page 37: ... distilled water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell After batteries are fully charged fill each cell to the bottom of the filler tube Do not over fill the batteries Do not add acid to batteries Keep the Batteries Charged Batteries should be charged each time that a machine is used for more than 1 hour orwhentheBatteryMe...

Page 38: ...efore testing There are 2 ways to find a dead cell Use a hydrometer to check the specific gravity or state of charge of the fluid in each cell A dead cell is one that reads 50 points or more lower than the other cells Use a volt meter to check the voltage of each battery with the brush and vac motors running The battery with the dead cell will read 1 or 2 volts lower than the other batteries in th...

Page 39: ...40 FORM NO 56043025 BA 700 800 1000 28LX 32LX 38LX 280HD 320HD 380HD NOTES ...

Page 40: ...Circuit Breaker 5 Amp Control Circuit 4 Circuit Breaker 25 Amp Wheel Drive 5 Circuit Breaker 25 Amp Vacuum Motor 6 Circuit Breaker 80 Amp Brush Motor 7 Solenoid Vac Motor 8 Solenoid Brush Motor 9 Solenoid Wheel Drive Motor 10 Solution Solenoid Valve 11 Vacuum Motor 12 Actuator Motor Brush Lift 13 Wheel Drive Motor 14 Brush Motor 15 Potentiometer 5K Ohm 16 Charger Interlock Switch 17 Main Key Switc...

Page 41: ... BRN WHT ORN WHT GRN BLU R3 H2 K5 X7 M3 X6 R2 S5 YEL WHT L RED F2 D5 F5 BRN YEL BRN RED 27 F3 F4 2 YEL BLK 3 RED K1 X2 K4 BLK 4 X5 X5 X3 M4 M1 RED RED BLK BLK VIO BRN VIO VIO 2 3 4 P2 BLK BLK BLK BLK K1 D1 VIO VIO GRN BLU VIO S2 1 2 3 4 5 6 1 2 3 4 5 6 BRN WHT BA 700 Before SN 1082069 BA 800 BA 1000 Before SN 1081111 BRN WHT BLK K2 D2 BLK K3 D3 M2 K2 1 6 2 5 3 4 E YEL VIO YEL BLK BLK K3 VIO VIO OR...

Page 42: ... BRN WHT 19D B WHT BLK 90B B WHT BLK 90B A BLK 0A B D5 YEL 4A B BLK OC B BRN WHT 19B B BRN WHT 19A B BRN WHT 19B B 3 2 1 6 5 4 YEL VIO 47A B E RED GRN 25B A RED GRN 25A A BLK 0L A K2 D3 D2 BLK 0G B BLK 0F B ORN BLK 30B B 30A B BLK 0E A VIO 7H B VIO 7G B GRN BLU 56A B BLK 0E B BLK 0D B RED BLK 20B B RED BLK 20A A 20A B BLK 0D A BLK 0C A VIO 7G A VIO 7F A WIRING DIAGRAM SCHEMATIC BA 700 s Before SN ...

Page 43: ... WHT FWD OFF REV BRN WHT ORN WHT GRN BLU R3 H2 K5 X7 M3 X6 R2 S5 YEL WHT D2 L RED F2 D5 F5 BRN YEL BRN RED 27 F3 F4 2 YEL BLK 3 RED K1 X2 K4 BLK 4 X5 X5 X3 M4 M1 IN 2 IN 1 TIMER OUT DIR MOTOR MOTOR B B RED RED BLK BLK VIO BRN VIO VIO 2 3 4 P2 BLK BLK BLK BLK K1 D1 VIO VIO BLK VIO S2 1 2 3 4 5 6 1 2 3 4 5 6 RED WHT WHT BLK Convertamatic 28 32 38LX Before SN 1082119 Hydro Retriever 280 320 380HD Bef...

Page 44: ...BLK 40A B 3 3 BLK 0G B B B M1 M2 P2 P3 1 1 REV OFF FWD 2 5 4 6 1 3 2 5 4 6 3 1 On 28 IN 700 MM Models Connect Cable 3 to 0n 32 38 IN 800 1000 MM Models Connect Cable 3 to WHT GRN BLK 1 2 3 4 1 2 3 A RED RED RED 4 X10 4 X11 X8 X9 M VIO 7C B BRN WHT 19C A R3 D5 RED GRN 25A A BLK 0C A R1 WIRING DIAGRAM SCHEMATIC Convertamatic 28 32 38LX Before SN 1082119 Hydro Retriever 280 320 380HD Before SN 108211...

Page 45: ...O K5 D4 E X10 B B M1 M2 P2 P1 1 1 A BLK GRN BLU VIO BLK GRN WHT FWD OFF REV BRN WHT ORN WHT GRN BLU H2 K5 X7 M3 X6 R2 S5 YEL WHT D2 L RED F2 F5 BRN YEL BRN RED 27 F3 F4 2 YEL BLK 3 RED K1 X2 K4 BLK 4 X5 X5 X3 M4 M1 IN 2 IN 1 TIMER OUT DIR MOTOR MOTOR B B WHT BLK RED RED BLK BLK VIO BRN VIO VIO 2 3 4 P2 BLK BLK BLK BLK K1 D1 VIO VIO BLK S2 1 2 3 4 5 6 1 2 3 4 5 6 BLK VIO D5 RED RED WHT RED WHT VIO ...

Page 46: ...VIO 7C B VIO 7E A WHT BLK 90A B RED GRN 25A A RED GRN 25B A BLK 0F A BLK 0G A YEL WHT 49B B YEL WHT 49B A YEL WHT 49A A VIO 7G A YEL BLK 40A B 3 3 BLK 0B B B B M1 M2 P2 P3 1 1 REV OFF FWD 2 5 4 6 1 3 2 5 4 6 3 1 On 28 IN 700 MM Models Connect Cable 3 to 0n 32 38 IN 800 1000 MM Models Connect Cable 3 to WHT GRN BLK 1 2 3 4 1 2 3 A RED RED RED 4 X10 4 X11 X8 X9 M WIRING DIAGRAM SCHEMATIC All Models ...

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