BA 500
Contents
1. 18 Note All references to right left front or rear in this manual are as seen from the operator s stand point SAFETY SYMBOLS Nilfisk uses the symbols below to signal potentially dangerous conditions Always read this information carefully and take the necessary steps to protect personnel and property A DANGER used to warn of immediate hazards that will cause severe personal injury or death WARNING used to call attention to a situation that could cause severe personal injury A CAUTION used to call attention to a situation that could cause minor personal injury or damage to the machine or other property GENERAL SAFETY INSTRUCTIONS WARNING Keep sparks flame and smoking materials away from the batteries Explosive gases are vented during normal operation Remove all jewelry when working near electrical components Disconnect one of the battery terminals when servicing electrical components Never work under a machine without safety stands or blocks to support the machine AX CAUTION Carefully read all instructions pertaining to a service function before performing that function Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts 1 500 Service Manual SPECIFICATIONS SPECIFICATIONS Dimensions English Metric Scrub Brush Diameter 20 inches 51 cm Scrub Brush Path 20 inches 51 c2. t work check circuit breaker for continuity FIGURE 2 Wheel Drive Circuit Breaker 2 Defective 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 500 Service Manual 18 WHEEL DRIVE SYSTEM TROUBLESHOOTING continued 3 Defect in potentiometer mechanism follow instructions below Make sure that the orange yellow and green wires are firmly connected to the potentiometer see Figure 3 See Figure 3 Check for loose set screws in pulley If the wires and set screws both secure follow steps below Remove the plastic cover from the speed control Disconnect plug A from the speed control Connect an ohmmeter to the green and orange wires NOTE inserting the ends of paper clips into the plug will help in the attachment of the test leads The meter should read 2400 2600 ohms in neutral and increase to 5000 ohms when the twist grips are turned to the full forward position If you do not get these readings follow potentiome
3. 500 Service Manual BATTERIES BATTERY MAINTENANCE continued Keep the Batteries Clean Use a damp cloth to wipe dirt and liquid from the top of the batteries Battery terminals must be clean and tight If the top of the batteries are wet after charging the batteries have probably been over filled 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 s in the battery system that is one or more cell s that is putting out less voltage than the other cells Note Always charge batteries before 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 the system If the batteries in the machine more than 1 year old it s usually best to replace the whole set rather than replacing just one battery 500 Service Manual 22
4. contact skin or eyes Explosive hydrogen gas is vented from inside the battery caps This gas can be ignited by any electrical arc spark or flame When working with batteries Remove all jewelry Wear safety glasses Do not smoke Do not allow tools to touch more than one battery terminal at a time Work in a well ventilated area BATTERY MAINTENANCE Proper maintenance of electric vehicle batteries can greatly extend their life There are 3 simple rules for good battery maintenance 21 Maintain Proper Electrolyte Level Use distilled water in batteries whenever possible If batteries are discharged add just enough water to cover the plates in each cell If 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 Machine operators should tip the solution tank forward and the recovery tank to the side of the machine for charging to avoid a concentrated build up of hydrogen gas Operators should follow the instructions provided with their specific battery charger to determine how long the batteries should be charged Even when a machine is stored the batteries should be charged once a month to prevent the batteries from sulfating Almost all battery caps are vented so there s no need to loosen or remove them for charging
5. the squeegee hose See Figure 1 Remove chain guard K snaps in place Loosen 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 Disconnect the master link on the chain and remove the chain Disconnect the drive motor from the wiring harness Remove the 2 4 bolts and nuts and remove the drive motor from the machine Remove the old drive motor from the motor mount and install the new motor on the mount Remove the chain guard from the old motor and install it on the new one Follow steps 1 6 in reverse order to reassemble Test the drive system for proper operation DRIVE CHAIN REPLACEMENT OR ADJUSTMENT Replacement Refer to steps 1 3 amp 4 of the Drive Motor Replacement section for instructions Follow these steps in reverse order to reassemble 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 BA500 Service Manual WHEEL DRIVE SYSTEM TROUBLESHOOTING Problem No wheel drive forward or reverse Possible Cause amp Remedy 1 Tripped wheel drive circuit breaker see Figure 2 press reset button if wheel drive still doesn
6. NILFISK BA 500 Service Manual ORDER PARTS Online www Phone 918 254 5161 A nterprises Form Number 043023 12 94 Model 66324400 TABLE OF CONTENTS Batteries 21 Brush Drive Belt Adjustment Or Replacement 7 Brush Drive Motor Carbon brush Inspection 8 Brush Drive Motor Replacement 8 Brush Drive System Maintenance 7 Brush Drive System Troubleshooting 10 Differential Replacement suds Means 16 Potentiometer Adjustment 20 1 Solenoid Valve Removal Disassembly amp Cleaning 4 Solution System heel ren near ae aaa 4 Solution System Troubleshooting 6 Specifications amp Maintenance 2 SOUSEGSS ACIUSUMONE 13 Vacuum Motor Removal 12 Vacuum System Maintenance dene endemic 11 Vacuum System Troubleshooting 14 Wheel Drive Chain Replacement Or Adjustment 17 Wheel Drive Motor Replacement 17 Wheel Drive System Troubleshooting
7. back flush dirt down and out of squeegee hose A Remove cover from the recovery tank see Figure 1 Rinse all dirt from cage E and ball Check the gasket on recovery tank cover It must seal air tight against the top of the tank Check drain hose cap 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 11 500 Service Manual VACUUM SYSTEM VACUUM MOTOR REMOVAL FIGURE 2 1 Drain the recovery tank and tip it to the side of the machine 2 Drain the solution tank disconnect the hose from the bottom of the tank and remove the tank from the machine 3 Disconnect one of the battery cables 4 Figure 2 Remove the 4 screws lift cover H off of the machine along with bracket 5 Figure 3 Remove the 4 J screws 6 Disconnect the vacuum motor wiring connector FIGURE 3 500 Service Manual 12 VACUUM SYSTEM SQUEEGEE ADJUSTMENT 1 Adjust the large knob on the back of the squeegee mount until both front and rear blades touch the floor equally FIGURE 4 13 500 Service Manual VACUUM SYSTEM TROUBLESHOOTING Problem Machine will not pick up water water flows around ends of squeegee Possible Cause and Remedy 1 2 Cap for
8. ircuit Breaker 2 Defective vacuum switch see Figure 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 replace solenoid FIGURE 6 Vacuum Motor Switch 15 500 Service Manual WHEEL DRIVE SYSTEM DIFFERENTIAL REPLACEMENT 1 Drain the tanks remove the batteries and tip the machine up on it s nose 2 Figure 1 Remove chain guard K snaps in place Loosen the chain tensioning bolt 3 Disconnect the master link in the chain and remove the chain FIGURE 1 ia es Ay gt 4 Remove the bolts and remove the wheels 5 Remove the 6 differential mounting bolts and nuts bushings Remove the differential from the machine 6 Remove the sprocket E collars 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 Follow steps 1 5 in reverse order to reassemble Refer to the Drive Chain Replacement Or Adjustment section for proper chain tension 8 the drive system for proper operation BA 500 Service Manual 16 WHEEL DRIVE SYSTEM DRIVE MOTOR REPLACEMENT 1 Drain the tanks remove the batteries and tip the machine up on it s nose Disconnect the squeegee lift cable and
9. m Scrub Brush Pressure 70 Ibs 32 kg Scrub Brush Speed 190 rpm 190 rpm Squeegee 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 sq ft 697 m2 per hour Machine Weight 266 105 121 kg net w o batteries General Specifications 558 Ibs 253 kg 376 Ibs 175 kg 350 Ibs 159 kg w four 244 AH batteries w two 93 AH batteries shipping weight Ss lt Brush Motor Wheel Drive Motor Vacuum Motor Brush Drive Sound Level Squeegee Type Speed Control Batteries 24 volt 1 2 hp de motor 24 volt 1 4 hp dc motor 24 volt 3 4 hp de motor Belt drive 68 2 db A 3 ft 9m using pads 68 9 db A using prolene scrub brushes 4 sided curved pivot type Electronic fully variable forward reverse 4 6 volt 244 AH std 2 12 volt 93 AH opt 500 Service Manual 2 MAINTENANCE 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 squeegee X Charge the batteries X Check battery water level X Lubrication X Vacuum motor carbon brushes X seseosecoosooocooosocosososooosososooosocesooosocososesooososoesooosocesoossooeoooscoosoooeooos oes En
10. m Squealing noise when brush is lowered Possible Cause and Remedy 1 Loose belt adjust belt tension Problem Brush motor will not start when twist grips are turned Possible Cause and Remedy 1 Tripped brush motor circuit breaker see Figure 7 press the reset button check circuit breaker for continuity Defective brush motor solenoid see Figure 7 replace solenoid Defective brush motor switch see Figure 7 replace switch Defective brush motor remove motor repair or replace Defective speed control or potentiometer replace speed control or potentiometer FIGURE 7 Brush Drive Solenoid Brush Motor Switch 500 Service Manual 10 VACUUM SYSTEM MAINTENANCE FIGURE 1 Whenever the vacuum system does not perform properly the entire system should be cleaned and inspected 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 Figure 1 Disconnect squeegee hose A CAUTION Do not flush hose unless it is disconnected from the vacuum motor 4 6 from left side of recovery tank cover Park the machine outside or near a floor drain and use a garden hose to
11. r instructions Defective solenoid valve Replace the solenoid valve See the Solenoid Valve Removal section for instructions 500 Service Manual 6 BRUSH DRIVE SYSTEM MAINTENANCE Once every six months 1 Check the belt tension adjust if necessary Once a year 1 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 BELT ADJUSTMENT OR REPLACEMENT FIGURE 1 1 Drain the solution and recovery tanks 2 See Figure 1 Tip the machine back as shown and place a jack stand under the front end 3 Figure 2 Turn nut A counterclockwise to loosen the belt tension FIGURE 2 4 Remove screw and remove the idler assembly and the belt from the machine Remove E bolts and remove the belt from the idler 5 Follow steps in reverse order to reassemble Tighten nut until the tension spring is 2 1 2 inches 63 5 mm long Test the brush drive system to make sure it operates properly 7 BA500 Service Manual BRUSH DRIVE SYSTEM BRUSH DRIVE MOTOR CARBON BRUSH INSPECTION 1 Remove the brush drive motor See the Brush Drive Motor Replacement section for instructions 2 See Figure 3 Place the brush drive motor in a vice as shown Be careful not to damage the pulley FIGURE 3 FIGURE 4 3 Figure 4 Remove 2 nuts and remove the end bell from the motor 4 Remove and measure the carbon brushes If they are wo
12. recovery tank drain hose not sealing air tight install cap 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 Damaged gasket on recovery tank cover replace gasket Low battery voltage charge or replace batteries Vacuum motor defective repair or replace vacuum motor Problem Water in vacuum motor Possible Cause and Remedy 1 Operator using high sudsing detergent use low sudsing detergent or add a defoaming chemical to the recovery tank Vacuum leak in recovery tank drain hose or cap replace hose or cap Vacuum shut off float ball not closing clean or replace float ball and cage mounted on recovery tank cover Problem Float closes before tank is full Possible Cause and Remedy 1 2 Foam in recovery tank advise operator to use low sudsing detergent or add a defoaming chemical to the recovery tank Cage around vacuum shut off float clogged disconnect hoses from recovery tank cover remove the cover and clean or replace the float cage 500 Service Manual 14 VACUUM SYSTEM TROUBLESHOOTING continued Problem Vacuum motor will not run when squeegee is lowered FIGURE 5 Possible Cause and Remedy 1 Tripped vacuum motor circuit breaker see Figure 5 press reset button check circuit breaker for continuity Vacuum Motor Solenoid Vacuum Motor C
13. rn 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 5 Follow steps 1 3 in reverse order to reassemble 6 Testthe motor to make sure it operates properly BRUSH DRIVE MOTOR REPLACEMENT 1 Drain the solution and recovery tanks and remove the solution tank from the machine 2 Tip the recovery tank to the side and disconnect the batteries 3 Remove the vacuum motor See the Vacuum System section for instructions 4 Disconnect the wires from the brush drive motor Take note of which wire color goes to each terminal for reassembly 500 Service Manual 8 BRUSH DRIVE SYSTEM BRUSH DRIVE MOTOR REPLACEMENT continued 5 See Figure 5 Tip the machine back as FIGURE 5 shown and place a jack stand under the front end 6 Figure 6 Turn nut counterclockwise to loosen the belt tension FIGURE 6 7 Remove screw the idler assembly and the belt from the machine 8 Remove 2 4 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 9 Remove the pulley from the old motor and install it on the new one 10 Follow steps 1 7 in reverse order to reassemble Tighten nut G until the tensioning spring is 2 1 2 inches 63 5 mm long 11 Test the brush drive system 9 BA500 Service Manual BRUSH DRIVE SYSTEM TROUBLESHOOTING Proble
14. ter adjustment instructions If you do get these readings go to the next test Connect an ohmmeter to the green and yellow wires The meter should read 2400 2600 ohms in neutral and decrease to 100 300 ohms when the twist grips are turned to the full forward position If you do not get these readings follow potentiometer adjustment instructions If you do get these readings the potentiometer is OK replace the speed control FIGURE 3 Yellow 19 500 Service Manual 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 1 Remove the back panel from the control handle 2 Figure 3 Loosen the 2 set screws in pulley B 3 Remove the plastic cover from the speed control 4 Carefully pull connector off the speed control pull toward back of machine 5 an ohmmeter on 0 x 100 scale to the green and yellow wires at the connector 6 Turn the potentiometer shaft until the meter reads between 2400 and 2600 ohms 7 Without turning the potentiometer shaft tighten the set screws in pulley 8 the drive system for proper operation before installing speed control cover and handle cover BA500 Service Manual 20 BATTERIES A WARNING Use extreme caution when working with batteries Sulfuric acid in batteries can cause severe injury if allowed to
15. terprises Inc Phone 918 254 5161 4 000000000000000 00 00 0 0 0000000660060 00 00 00 00006000000000000600006 00600606 0 3 500 Service Manual SOLUTION SYSTEM MAINTENANCE The solution system should be thoroughly flushed once a week To flush the solution system 1 Empty the solution tank using the clear plastic drain hose on back of machine This automatically flushes loose dirt from solution filter Put clean warm water into the solution tank and let it drain through the drain hose Put the plug in the drain hose and put about 2 inches of clean water in the solution tank Put the machine controls in the following positions Key Switch ON Solution Switch on left side of handle ON Brush 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 SOLENOID VALVE REMOVAL 1 Remove the vacuum motor See Vacuum System chapter for instruc tions ld FIGURE 1 Disconnect the solution valve and mercury switch wiring connectors See Figure 1 Remove hoses A and Remove 2 bolts and remove the solution valve and bracket from the machine Front 500 Service Manual 4 SOLUTION SYSTEM SOLENOID VALVE DISASSEMBLY AND CLEANING 1 Remove the solenoid valve See
16. the Solenoid Valve Removal section for instructions 2 See Figure 2 Remove the 2 screws and nuts and disassemble the valve be careful not to lose any internal parts 3 Thoroughly wash dirt from block E and diaphram 4 After reassembling test the solenoid valve for proper operation FIGURE 2 5 BA500 Service Manual SOLUTION SYSTEM TROUBLESHOOTING Problem No solution flow Possible Cause and Remedy 1 Machine 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 Brush drive lowered Twist Grips Forward Flow control lever on right side of control handle UP Clogged 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 Clogged Solenoid Valve Remove disassemble and clean the solenoid valve See the Solenoid Valve Disassembly and Cleaning section for instructions Defective Speed Control Replace speed control Problem Solution leaks in OFF position Possible Cause and Remedy 1 2 Dirt in solenoid valve Remove disassemble and clean the solenoid valve See the Solenoid Valve Disassembly and Cleaning section fo
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