Nilfisk-Advance CA 551 Page 110 Service Manual Download

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ELECTRICAL SYSTEM

ENGLISH

SERVICE MANUAL

108

909 6756 000(

5)2010-03

BA 451 / BA 451D / BA 531 / BA 531D / BA 551 / BA 551D / BA 551CD / BA 611D

CA 451 / CA 531 / CA 551

BAT

EV1

ES2

EB1

ES1

S301577

COMPONENT LAYOUT (For BA 451, BA 531, BA 551)

Key:

BAT

24 V battery

Battery connector

Battery charger connector

Battery charger (optional)

Deck connector

EB1

Function electronic board

ES1

Brush electromagnetic switches

ES2

Vacuum system relay

EV1

Water solenoid valve

Deck fuse

Vacuum system fuse

Signal circuit fuse

Hour counter (optional)

Brush/pad-holder motor

Vacuum system motor

NOTE

Figure showing

BA 551

Summary of Contents for CA 551

Page 1: ...BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 SERVICE MANUAL 909 6756 000 Edition 5 2010 03 setting standards Printed in Italy ...

Page 2: ......

Page 3: ...E For BA 551 BA 551D BA 551CD BA 611D 22 MACHINE NOMENCLATURE For CA 451 CA 531 25 MACHINE NOMENCLATURE For CA 551 27 SOLUTION CLEAN WATER SUPPLY SYSTEM 29 SOLUTION CLEAN WATER TANK AND SUPPLY SYSTEM CLEANING All models 29 SOLUTION FILTER CLEANING For BA 451 BA 451D BA 531 BA 531D CA 451 CA 531 without EcoFlex system 29 SOLUTION FILTER CLEANING For BA 551 BA 551D BA 551CD BA 611D CA 551 without Ec...

Page 4: ... 531 CA 551 66 CHECK REPLACEMENT ADJUSTMENT OF DRIVING BELTS FROM MOTORS TO CYLINDRICAL BRUSHES For BA 551CD 67 BRUSH ENABLING MICROSWITCH ADJUSTMENT REPLACEMENT For BA 451D BA 531D BA 551D BA 551CD BA 611D 69 TROUBLESHOOTING 74 RECOVERY WATER SYSTEM 72 RECOVERY WATER TANK AND VACUUM GRID CLEANING AND COVER GASKET CHECK All models 72 SQUEEGEE CLEANING CHECK REPLACEMENT AND SQUEEGEE BLADE REPLACEME...

Page 5: ...EMENT For BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D 99 FUSE CHECK REPLACEMENT For CA 431 CA 531 CA 551 100 BRUSH MOTOR ELECTROMAGNETIC SWITCH DISASSEMBLY ASSEMBLY For BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D 101 DRIVE SYSTEM ELECTRONIC BOARD DISASSEMBLY ASSEMBLY For BA 451D BA 531D BA 551D BA 551CD BA 611D 103 FUNCTION ELECTRONIC BOARD DISASSEMBLY ASSEMBLY ...

Page 6: ...Department BA 451 BA 451D BA 531 BA 531D User Manual Form Number 909 6748 000 BA 451 BA 451D BA 531 BA 531D Spare Parts List Form Number 909 6749 000 BA 551 BA 551D BA 551CD BA 611D User Manual Form Number 909 6752 000 BA 551 BA 551D BA 551CD BA 611D Spare Parts List Form Number 909 6753 000 CA 451 CA 531 User Manual Form Number 909 6750 000 CA 451 CA 531 Spare Parts List Form Number 909 6751 000 ...

Page 7: ...hine must be used by properly trained operators only Children or disabled people cannot use this machine Do not wear jewels when working near electrical components Do not work under the lifted machine without supporting it with safety stands Do not operate the machine near toxic dangerous flammable and or explosive powders liquids or vapours This machine is not suitable for collecting dangerous po...

Page 8: ...and protections Do not use the machine as a means of transport Do not allow the brushes to operate while the machine is stationary to avoid damaging the floor In case of fire use a powder fire extinguisher not a water one Do not tamper with the machine safety guards and follow the ordinary maintenance instructions scrupulously Do not allow any object to enter into the openings Do not use the machi...

Page 9: ...ded according to law in force Improper connection can cause electric shock Do not tamper with the power supply cable plug If the power supply cable plug cannot be connected to the outlet have new grounded outlet installed by a qualified technician according to the law in force Before connecting the power supply cable to the electrical mains check that frequency and voltage shown on the machine ser...

Page 10: ...1 Sound pressure level at the operator s position ISO 11201 ISO 4871 LpA 66 dB A 3dB A Sound pressure level to the machine ISO 3744 ISO 4871 LwA 84 dB A Vibration level at the operator s arms ISO 5349 1 98 4 in s2 2 5 m s2 Standard batteries DRY 2 x 12 V 24 V 110 Ah 5 h Standard batteries autonomy 3 2h 2 6h 3 2h 2 6h Battery compartment size width x length x height 13 8 x 13 8 x 11 8 in 350 x 350 ...

Page 11: ...ure on the ground 174 psi 1 2 N mm2 Rear wheel diameter 3 9 in 100 mm Rear wheel specific pressure on the ground 667 psi 4 6 N mm2 Minimum turning radius 27 5 in 700 mm Vacuum system motor power 0 44 hp 330 W Drive system motor power 0 27 hp 200 W Drive speed variable da 0 a 3 5 MPH da 0 a 5 6 km h Working gradeability 2 1 Sound pressure level at the operator s position ISO 11201 ISO 4871 LpA 66 d...

Page 12: ...s and with empty tanks 194 0 lb 88 kg 225 0 lb 102 kg Maximum weight with batteries and full tanks 520 3 lb 236 kg 551 1 lb 250 kg Brush motor power 0 64 hp 480 W 0 47 hp 350 W Brush speed 153 rpm 230 rpm Brush pad holder pressure with extra pressure function turned off 45 2 lb 20 5 kg Brush pad holder pressure with extra pressure function turned on 61 3 lb 27 8 kg Technical data for machines with...

Page 13: ...king gradeability 2 1 Sound pressure level at the operator s position ISO 11201 ISO 4871 LpA 68 dB A 3dB A Sound pressure level to the machine ISO 3744 ISO 4871 LwA 84 dB A Vibration level at the operator s arms ISO 5349 1 98 4 in s2 2 5 m s2 Total consumption in work condition 6 A 50Hz 7 A 60Hz Vacuum system circuit capacity 1 29 Mpa 1 316 mm H2 O Cleaning width 18 0 in 450 mm 21 0 in 530 mm Sque...

Page 14: ...00 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DIMENSIONS BA 451 1190 mm 46 8 in 760 mm 30 0 in 1058 5 mm 41 6 in 512 mm 20 1in DIMENSIONS BA 451D 1190 mm 46 8 in 760 mm 30 0 in 1058 5 mm 41 6 in 512 mm 20 1in ...

Page 15: ...BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 13 DIMENSIONS BA 531 1228 mm 48 3 in 760 mm 30 0 in 1058 5 mm 41 6 in 540 mm 21 2 in DIMENSIONS BA 531D 1228 mm 48 3 in 760 mm 30 0 in 1058 5 mm 41 6 in 540 8 mm 21 2 in ...

Page 16: ...0 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DIMENSIONS CA 451 1147 mm 45 1 in 760 mm 30 0 in 1058 5 mm 41 6 in 512 mm 20 1in P100200 DIMENSIONS CA 531 1185 mm 46 6 in 760 mm 30 0 in 1058 5 mm 41 6 in 541 mm 21 3 in P100201 ...

Page 17: ...1 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 15 DIMENSIONS BA 551 1323 mm 52 1 in 760 mm 30 0 in 1088 mm 42 8 in 541 mm 21 3 in P100202 DIMENSIONS BA 551D 1323 mm 52 1 in 760 mm 30 0 in 1088 mm 42 8 in 541 mm 21 3 in P100202 ...

Page 18: ...0 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DIMENSIONS BA 551CD 1253 mm 49 3 in 760 mm 30 0 in 1088 mm 42 8 in 575 5 mm 22 7 in P100203 DIMENSIONS BA 611D 1311 mm 51 6 in 810 mm 32 in 1088 mm 42 8 in 646 mm 25 4 in P100204 ...

Page 19: ... SERVICE MANUAL ENGLISH BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 17 DIMENSIONS CA 551 1306 mm 51 4 in 760 mm 30 0 in 1088 mm 42 8 in 541 mm 21 3 in P100205 ...

Page 20: ...ng Tank and vacuum grid with float cleaning and cover gasket check Squeegee blade check and replacement EcoFlex system cleaning and draining optional Solution clean water filter cleaning Battery WET fluid level check Vacuum system motor filter cleaning Screw and nut tightening check 1 Brush pad holder motor carbon brush check or replacement Vacuum system motor carbon brush check or replacement Dri...

Page 21: ...ate 33 Serial number plate technical data conformity certification 34 Plug for squeegee vacuum hose cleaning 35 Vacuum grid with automatic shut off float 36 Solution filler neck 37 Foam filter 38 Compensation hole 39 Recovery water tank lifted 40 Tank lifting handle 41 Lifted tank tie rod 42 Vacuum system motor cover 43 Vacuum system motor sound deadening filter 44 Detergent tank 45 Detergent tank...

Page 22: ...1 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 MACHINE NOMENCLATURE For BA 451 BA 451D BA 531 BA 531D Continues 21 22 24 23 1 2 3 4 5 6 7 10 11c 11b 11 12 27 15 25 26 13 55 14 19 18 20 16 17 11a 26 42 58 40 41 44 43 52 53 45 47 48 46 57 49 50 55 51 54 29 56 28 38 37 9 31 32 33 30b 30a 39 34 35 36 S301514 ...

Page 23: ...CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 21 NOMENCLATURA DELLA MACCHINA Per BA 451 BA 451D BA 531 BA 531D Continua BA 451 BA 531 BA 451D BA 531D 94 93 92 91 90 71 72 73 81a 81b 81c 82a 82c 82b 74 79 81 82 71 72 73 81a 81b 81c 82a 82c 82b 74 75 76 84 83 78 77 79 80 81 82 85 S301515 ...

Page 24: ...cover gasket 31 Cover movable retaining plate 32 Cover fixed retaining plate 33 Serial number plate technical data conformity certification 34 Plug for squeegee vacuum hose cleaning 35 Vacuum grid with automatic shut off float 36 Solution front filler neck 37 Foam filter 38 Compensation hole 39 Recovery water tank open 40 Tank lifting handle 41 Lifted tank tie rod 42 Vacuum system motor cover 43 V...

Page 25: ...CA 551 909 6756 000 5 2010 03 23 MACHINE NOMENCLATURE For BA 551 BA 551D BA 551CD BA 611D Continues 29 28 21 20 56 18a 19a 14 22 24 23 1 2 3 4 5 6 7 8 10 9 11c 11b 11a 11 16 17 54 5513 26 15 12 25 27 26 19b 18c 39 30b 38 37 35 36 34 31 32 33 30a 46 53 52 18b 19a 47 58 43 42 40 41 48 44 45 47 46 50 51 49 57 48 45 S301516 ...

Page 26: ... 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 MACHINE NOMENCLATURE For BA 551 BA 551D BA 551CD BA 611D Continues BA 511 BA 551D BA 551CD BA 611D 94 93 92 91 90 71 72 73 81a 81b 81c 82a 82c 82b 74 79 81 82 71 72 73 81a 81b 81c 82a 82c 82b 74 75 76 84 83 78 77 79 80 81 82 85 S301517 ...

Page 27: ...er 23 Document retainer optional 24 Squeegee 25 Squeegee mounting handwheels 26 Squeegee balance adjusting handwheel 27 Machine straight forward movement adjusting handwheel 28 Machine forward speed adjustment handwheel 29 30a Recovery water tank cover opened to be cleaned 30b Recovery water tank cover completely opened Tank cover gasket 31 Cover movable retaining plate 32 Cover fixed retaining pl...

Page 28: ...1 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 MACHINE NOMENCLATURE For CA 451 CA 531 Continues 21 22 24 23 1 2 60 59 10 11 26 27 25 15 26 55 14 19 18 20 13 17 16 37 38 9 32 31 30b 30a 39 61 34 35 36 55 54 56 28 11b 11a 33 29 42 40 41 43 64 44 82 79 63 62 82a 82c 82b S301518 ...

Page 29: ...holder 23 Document retainer optional 24 Squeegee 25 Squeegee mounting handwheels 26 Squeegee balance adjusting handwheel 27 Machine straight forward movement adjusting handwheel 28 Machine forward speed adjustment handwheel 29 30a Recovery water tank cover opened to be cleaned 30b Recovery water tank cover completely opened Tank cover gasket 31 Cover movable retaining plate 32 Cover fixed retainin...

Page 30: ...531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 MACHINE NOMENCLATURE For CA 551 Continues 24 23 1 22 2 60 59 8 10 11 17 16 14 26 27 25 15 26 13 55 54 33 29 56 30a 61 39 30b 9 11b 11a 19 18 20 21 34 35 36 28 38 37 32 31 18 42 40 41 43 64 44 82 79 63 62 82a 82c 82b S301519 ...

Page 31: ...off the switches 71 and 73 For CA 451 CA 531 CA 551 Disconnect the power supply cable 59 from the electrical mains Clean the tank 20 with clean water 6 Start the machine as shown in the User Manual and keep it running until the solution clean water tank is completely empty 7 Clean the solution filter see the following procedure 8 SOLUTION FILTER CLEANING For BA 451 BA 451D BA 531 BA 531D CA 451 CA...

Page 32: ...the ignition key 80 to 0 For BA 551 Turn off the switches 71 and 73 For CA 551 Disconnect the power supply cable 59 from the electrical mains Close the solution tap A under the machine left lower side The tap A is closed when it is on the position B and it is open 3 when it is on the position C Remove the transparent cover D then remove the filter strainer E Clean and install them on the support F...

Page 33: ...531 Disassembly Remove the brush 1 Lower the deck by pressing the pedal 11 2 Remove the screw A disconnect the connector B and recover the gasket 3 Disconnect the union C from the solenoid valve D and recover the gasket 4 Remove the screws E 5 Slightly lift the solenoid valve D disconnect the union F and recover the gasket 6 Recover the solenoid valve D 7 Assembly Assemble the components in the re...

Page 34: ...hout EcoFlex system Loosen the clamp A and disconnect the hoses B from the filter assembly C Disconnect the union D from the solenoid valve E and recover the gasket 4 Remove the screw F disconnect the connector G and recover the gasket 5 Remove the nuts H 6 7 For machines without EcoFlex system Remove the solenoid valve E with the hoses B If necessary separate the hoses B from the solenoid valve F...

Page 35: ...ter tap is stuck closed replace 2 The solenoid valve is broken or there is an open in the electrical connection replace the solenoid valve repair the electrical 3 connection There is debris in the solution tank clogging the output hole clean the tank 4 There are debris in the solution clean water hoses clogging the flow clean the hoses 5 THE SOLUTION CLEAN WATER REACHES THE BRUSH ALSO WHEN THE MAC...

Page 36: ...el floor 1 Turn the ignition key 80 to 0 2 Close the clean water tap A under the machine left lower side The tap A is closed when it is on the position B and it is 3 open when it is on the position C Remove the transparent cover D then remove the filter strainer E Clean and install them on the support F 4 NOTE The filter strainer E must be correctly positioned on the housing G of the support F Ope...

Page 37: ...nd check that the recovery water tank 21 is empty otherwise empty it with the drain hose 16 3 Grasp the handle 41 and carefully lift the tank 40 4 Slightly lift the hoses A then operating on the clean water filter assembly F unscrew the transparent cover B and remove 5 the filter strainer C Clean and install them on the support D NOTE The filter strainer C must be correctly positioned on the housi...

Page 38: ...nd remove the hose 48 from the tank 45 5 Remove the tank 45 by releasing it from the fasteners 6 Unscrew the plug A and wash the detergent tank B in the appointed detergent disposal area 7 If necessary remove the supply hose C and clean it especially in area of the vacuum end pipe D Install the supply hose C Check that the plug vent hole E is not clogged by driving in air and checking if it comes ...

Page 39: ...g led 78 to stop flashing and for the vacuum system to turn on 6 Collect the detergent remained on the floor 7 Turn the ignition key 80 to 0 8 Grasp the handle 41 and carefully lift the tank 40 then check that the hose 48 is empty otherwise perform steps 3 to 9 9 again NOTE The draining cycle lasts about 30 seconds then the vacuum function automatically turns on which allows to remove the detergen...

Page 40: ...covery water disposal area Turn the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor 2 Turn the ignition key 80 to 0 3 Grasp the handle 41 and carefully lift the tank 40 4 Disconnect the connector A 5 Loosen the clamps B and disconnect the hoses C from the water pump D 6 Remove the screws E 7 Remove the water pump D 8 Assembly Assemble the c...

Page 41: ...0 4 Unscrew the union A 5 Remove the detergent tank B 6 Remove the screws C 7 Slightly lift the tank holder D and mark the position of the connectors E and F to reinstall them correctly which must be 8 as follows Connector E white cable Connector F blue cable Disconnect the connectors E and F from the detergent pump G 9 Disconnect the hoses H from the relevant union 10 Remove the screws I and reco...

Page 42: ...UAL 40 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DETERGENT PUMP AND CHECK VALVE DISASSEMBLY ASSEMBLY For BA 451D BA 531D Continues B A C D C K G E F I G L J M K H J S301527 ...

Page 43: ...nk 40 4 Unscrew the union A 5 Remove the detergent tank B 6 Remove the screws C 7 Slightly lift the tank holder D and mark the position of the connectors E and F to reinstall them correctly which must be 8 as follows Connector E white cable Connector F blue cable Disconnect the connectors E and F from the detergent pump G 9 Disconnect the hoses H from the relevant union 10 Remove the screws I and ...

Page 44: ...2 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DETERGENT PUMP AND CHECK VALVE DISASSEMBLY ASSEMBLY For BA 551D BA 551CD BA 611D Continues A B C C D H M L J K G I F E G K J S301528 ...

Page 45: ...rgent hoses clogging the detergent flow clean the hoses 5 The detergent flow control switch is malfunctioning check that the warning led 78 turns on if necessary replace the function 6 electronic board The function electronic board is not set for the operation with EcoFlex system if present remove the jumper wire J4 7 behind the electronic board The function electronic board is faulty replace 8 TH...

Page 46: ...brushes pads because there may be sharp debris Remove the brushes pads as shown in the User Manual 1 Clean and wash the brushes pads with water and detergent 2 Check that the brush pads are integral and not excessively worn otherwise replace them 3 For 4 BA 551CD Remove the debris container A by pulling it on one side with the handle B Empty and wash the debris container A and then install it by e...

Page 47: ...mbly Drive the machine on a level floor 1 Remove the brushes pad holders as shown in the User Manual 2 Lower the brush pad holder deck by pressing the pedal 11 3 Remove the cotter pins B then remove the gas spring A 4 Disconnect the brush pad holder motor electrical connection D 5 Remove the screw E and disconnect the electrical connection F 6 Disconnect the solution hose connection G 7 Remove the...

Page 48: ...see the Squeegee Installation paragraph in the User Manual Disassembly Drive the machine on a level floor 1 Remove the brushes pad holders as shown in the User Manual Do not remove the cylindrical brushes 2 Lower the brush pad holder deck by pressing the pedal 11 3 Remove the cotter pins B then remove the gas spring A if present 4 Disconnect the brush pad holder motor electrical connection D 5 Dis...

Page 49: ... If the power supply cable 59 is on the holder 60 remove it 8 Move aside the recovery water drain hose 16 9 Remove the screws A and carefully move the panel B 10 Disconnect the brush motor wiring harness connections C from the electronic board D connections symbols F4 and 11 F5 Open the brush motor wiring harness clamps E 12 Open the brush motor wiring harness clamps F 13 Lower the deck by pressin...

Page 50: ...ANUAL 48 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH PAD HOLDER DECK DISASSEMBLY ASSEMBLY For CA 451 CA 531 CA 551 Continues A B A A A C D E E D F P H Q I H G S301532 ...

Page 51: ... from the detergent pump G Disconnect the hoses H from the union I and remove the tank holder D together with the detergent pump G Apply the amperometric pliers J on one cable K of the brush motor L 8 For 9 BA 451D BA 551D Turn the speed adjuster 4 to idle and turn the ignition key 80 to I Turn on the brush pad holder by pressing the switch 71 and check that the motor electrical input is 3 4 A at ...

Page 52: ...E MANUAL 50 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR ELECTRICAL INPUT CHECK For BA 451 BA 451D BA 531 BA 531D Continues B A I C H D C G H E F K L J S301533 ...

Page 53: ...rgent pump G Disconnect the hoses H from the union I and remove the tank holder D together with the detergent pump G Apply the amperometric pliers J on one cable K of the brush motor L 8 For 9 BA 551D Turn the speed adjuster 4 to idle and turn the ignition key 80 to I Turn on the brush pad holder by pressing the switch 71 and check that the motor electrical input is 3 4 A at 24 V Turn off 10 the b...

Page 54: ...H SERVICE MANUAL 52 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR ELECTRICAL INPUT CHECK For BA 551 BA 551D Continues A B C D C I H F E G K L J S301534 ...

Page 55: ...itch 71 Turn the ignition key 80 to 0 Remove the amperometric pliers A If the electrical input is higher perform the following procedures to detect and correct the abnormal input NOTE If the electrical input is higher than the maximum allowed value the 3 battery warning leds 81 flash simultaneously Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph Check if...

Page 56: ...1 Turn the ignition key 80 to 0 Remove the amperometric pliers A If the electrical input is higher perform the following procedures to detect and correct the abnormal input NOTE If the electrical input is higher than the maximum allowed value the 3 battery warning leds 81 flash simultaneously Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph Check if there...

Page 57: ...d D of the panel C 7 Apply the amperometric pliers E on one cable F connection symbols F4 or F5 of the brush motor 8 Connect the power supply cable 59 to the electrical mains 9 Turn on the brush by pressing the switch 62 and check that the motor electrical input is 3 4 A at 230 V Turn off the brush by 10 pressing the switch 62 Disconnect the power supply cable 59 from the electrical mains Remove t...

Page 58: ...SH SERVICE MANUAL 56 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR ELECTRICAL INPUT CHECK For CA 451 CA 531 CA 551 Continues A A D C B B D F E S301537 ...

Page 59: ...he connectors E and F to reinstall them correctly which must be as follows Connector E white cable Connector F blue cable Disconnect the connectors E and F from the detergent pump G Disconnect the hoses H from the union I and remove the tank holder D together with the detergent pump G Disconnect the battery connector 12 8 Remove dust and dirt from the motor carbon brush support area A 9 Disengage ...

Page 60: ...58 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT For BA 451 BA 451D BA 531 BA 531D Continues C H D C G H E F I J J M J M O L J K N S301539 ...

Page 61: ...o reinstall them correctly which must be as follows Connector E white cable Connector F blue cable Disconnect the connectors E and F from the detergent pump G Disconnect the hoses H from the union I and remove the tank holder D together with the detergent pump G Disconnect the battery connector 12 8 Remove dust and dirt from the motor carbon brush support area A 9 Disengage the fasteners K and L a...

Page 62: ... MANUAL 60 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT For BA 551 BA 551D Continues J J M J M O L J K N C D C I H F E G S301541 ...

Page 63: ...cially in the area of the protection clamp A 2 Remove the protection clamp A 3 For each carbon brush move the protection B and remove the screws C 4 Remove the carbon brushes D 5 Check if the carbon brushes D are worn Replace the carbon brushes when the contact with the motor armature is 6 insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring i...

Page 64: ...e carbon brushes 2 Remove four protection covers A by disengaging the fasteners 3 Remove the carbon brush nuts B with the lead in wires 4 Disengage the tabs C and remove the carbon brushes D 5 Check if the carbon brushes D are worn Replace the carbon brushes when the contact with the motor armature is 6 insufficient the carbon brushes are worn the carbon brush contact surface is not integral the t...

Page 65: ...BA 551 BA 551D Disassembly Remove the deck see the procedure in the relevant paragraph 1 At the workbench remove the screw A from the deck 2 Remove the hub assembly B with a puller 3 Remove the screws C 4 Remove the reduction unit D 5 If necessary remove the water distribution union E and flange F from the reduction unit 6 Assembly Assemble the components in the reverse order of disassembly 7 D E ...

Page 66: ...to be disassembled 2 Remove the case B 3 Loosen the nut C and move the pulley D to loosen the belt E 4 Remove the belt E 5 Remove the screws F 6 Remove the motor G 7 Assembly Assemble the components in the reverse order of disassembly and note the following 8 The electrical connections H of the motor G must be turned upwards The connection J of the carbon brush protection clamps I must be position...

Page 67: ... BA 611D Disassembly Remove the deck see the procedure in the relevant paragraph 1 At the workbench remove the screw A from the reduction unit which has to be disassembled 2 Remove the hub assembly B with a puller 3 Remove the screws C 4 Remove the reduction unit D 5 Recover the key E 6 Assembly Assemble the components in the reverse order of disassembly 7 D D E E C C B B A A S301546 ...

Page 68: ...the procedure in the relevant paragraph 1 At the workbench remove the screw A 2 Remove the hub assembly B with a puller 3 Remove the screws C 4 Remove the reduction unit D with the relevant wiring harness 5 Recover the key E 6 If necessary remove the solution hose E 7 If necessary remove the motor wiring harness G 8 Assembly Assemble the components in the reverse order of disassembly 1 NOTE Figure...

Page 69: ...ng to the following procedure 5 Check the tension of the belt G according to the following procedure 6 Replacement If the belt G is to be replaced loosen the nut D and move the pulley K to loosen the belt 7 Tension the belt according to the following procedure 8 Belt tensioning Check the tension of the belt C from motor to brush The tension is correct 9 When pressing the belt in its center with a ...

Page 70: ... 68 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 CHECK REPLACEMENT ADJUSTMENT OF DRIVING BELTS FROM MOTORS TO CYLINDRICAL BRUSHES For BA 551CD Continues B A D E E C F 5 mm S301548 ...

Page 71: ... fasten it with the screws then connect the connectors I Check that the actuator E of the microswitch F is in the housing G of the cam H when the drive paddle is released D 7 Check also that the cable contacts I are all opened use a tester Press the drive paddle D and check that the actuator E in the positions J and K activates the microswitch F a clicking 8 sound must be heard Check also that the...

Page 72: ... 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH ENABLING MICROSWITCH ADJUSTMENT REPLACEMENT For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues D C F I N H L E M M G K E J H G S301550 ...

Page 73: ...switch wiring harness is damaged repair 3 The function electronic board is damaged replace 4 The wiring harness between function electronic board and brush motor electromagnetic switch is damaged repair 5 The brush motor electromagnetic switch is damaged replace 6 The brush motor fuse is open replace 7 ONE BRUSH DO NOT ROTATE For models with two brushes Possible causes The motor carbon brushes are...

Page 74: ...loat D 4 Drain the water in the tank through the hose 16 5 If necessary release the fasteners E and open the grid D recover the float F clean all the components and then reinstall them Check the tank cover gasket G for integrity 6 NOTE The hole K allowing to compensate the air in the cover interspaces contributes to create vacuum in the tank If necessary replace the gasket G by removing it from it...

Page 75: ... Fig 1 or 2 of the front blade C and the edges F of the rear blade D lay down on the same level 9 along their length otherwise adjust their height according to the following procedure Release the tie rod G Fig 1 or 2 and loosen the wing nuts H Fig 1 or disengage the fasteners M Fig 2 and adjust the rear blade D Fig 1 or 2 then tighten the wing nuts or engage the fasteners and then engage the tie r...

Page 76: ...GLISH SERVICE MANUAL 74 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 SQUEEGEE CLEANING CHECK REPLACEMENT AND SQUEEGEE BLADE REPLACEMENT All models Continues S301552 ...

Page 77: ... water tank 21 with the hose 16 Drive the machine on a level floor 2 For 3 BA 451D BA 531D BA 551D BA 551CD BA 611DD Turn the ignition key 80 to 0 For BA 451 BA 531 BA 551 Turn off the switches 71 and 73 For CA 451 CA 531 CA 551 Disconnect the power supply cable 59 from the electrical mains For 4 CA 451 CA 531 CA 551 Open the recovery water tank cover 22 Remove the retaining plate 61 of the tank 4...

Page 78: ... 531 BA 551 Turn off the switches 71 and 73 Disconnect the battery connector 12 4 Grasp the handle 41 and carefully lift the tank 40 5 Apply the amperometric pliers A on one cable B of the batteries 6 For 7 BA 451D BA 531D BA 551D BA 551CD BA 611D Turn the ignition key 80 to I Turn on the vacuum system by pressing the switch 73 and check that the motor electrical input is 16 19 A at 24 V 8 Turn of...

Page 79: ...t the power supply cable 59 to the electrical mains 9 Turn on the vacuum system by pressing the switch 63 and check that the motor electrical input is 2 2 5 A at 230 V Turn off 10 the vacuum system by pressing the switch 63 Disconnect the power supply cable 59 from the electrical mains Remove the amperometric pliers E If the electrical input is higher perform the following procedures to detect and...

Page 80: ...H SERVICE MANUAL 78 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK For CA 451 CA 531 CA 551 Continues A A D C B B E F D S301554 ...

Page 81: ...r A press fitted from the vacuum system motor B 2 Remove the screws C 3 Disconnect the electrical connections D 4 Remove the carbon brushes E 5 Check the carbon brushes for wear Replace the carbon brushes when the contact with the motor armature is insufficient the 6 carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc If necessary replace the ca...

Page 82: ...rical mains For 4 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D Disconnect the battery connector 12 For 5 CA 451 CA 531 CA 551 Remove the retaining plate 61 of the tank 40 Grasp the handle 41 and carefully lift the tank 40 6 Remove the screws A and recover the washers 7 Remove the motor cover B 8 Remove the filter C and the gasket D 9 Remove the motor E or L the sound deadening pip...

Page 83: ...VICE MANUAL ENGLISH BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 81 VACUUM SYSTEM MOTOR DISASSEMBLY ASSEMBLY All models Continues L K J I E H G F A A B C D L S301556 ...

Page 84: ... cable 59 from the electrical mains Check that the springs A and B push the squeegee C on the floor correctly 3 If necessary disassemble and replace the springs according to the following procedure 4 Disassembly Remove the squeegee see the procedure in the relevant paragraph 5 Lift the deck by pressing the pedal 11 6 Grasp the handlebar 2 and lower the front part of the machine 7 Remove the cotter...

Page 85: ...ACUUMING Possible causes The vacuum grid with automatic shut off float is activated because the recovery water tank is full empty the recovery water 1 tank The vacuum grid with automatic shut off float is dirty or the vacuum pre filter is dirty clean 2 The tank cover is not correctly positioned adjust 3 The tank cover gasket is not efficient or the compensating hole is clogged repair clean 4 The v...

Page 86: ...llowing When the paddle H is released measure 2 5 KΩ 0 1 KΩ When the paddle H is completely pushed forward measure 5 0 KΩ 0 1 KΩ When the paddle H is completely pulled rearward measure 0 0 KΩ 0 1 KΩ If necessary to adjust the values loosen the screw O loosen the nut M and slightly turn the potentiometer N as necessary After adjusting tighten the nut M and the screw O To adjust the value when the p...

Page 87: ...1 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 85 SPEED POTENTIOMETER ADJUSTMENT REPLACEMENT For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues F E E J G G T P N M U O S Q H R I S301559 ...

Page 88: ...ter knob B 2 Unscrew the potentiometer mounting nut C 3 Remove the screws D and move the cover E 4 Cut the fastening clamp F and disconnect the potentiometer connector G 5 Open the clamp H 6 Remove the potentiometer with the relevant wiring harness I 7 Assembly Assemble the components in the reverse order of disassembly and note the following 8 Fasten the knob B with the potentiometer shaft L comp...

Page 89: ...ISH BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 87 MAXIMUM SPEED POTENTIOMETER DISASSEMBLY ASSEMBLY For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues G F I H E S301561 ...

Page 90: ...orming this procedure pay attention to the rotation of the driving wheel C Apply the amperometric pliers D on one cable E of the drive system motor 6 Turn the ignition key 80 to I 7 Turn the speed adjuster 4 to the maximum speed 8 With the help of an assistant who firmly keeps the machine by the handlebar push the drive paddle 3 completely forward and 9 check that the electrical input is 1 5 2 5 A...

Page 91: ...NGLISH BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 89 DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues C A E B D S301562 ...

Page 92: ...on a level floor Turn the ignition key 80 to 0 3 Disconnect the battery connector 12 4 Operating on the left side of the machine clean the drive system motor B in the area of the covers A 5 Unscrew the covers A and remove the carbon brushes C 6 Check if the carbon brushes C are worn Replace the carbon brushes when the contact with the motor armature is 7 insufficient the carbon brushes are worn th...

Page 93: ...ee the procedure in the relevant paragraph 2 Remove the batteries see the procedure in the relevant paragraph 3 Prepare an hoisting system A on which the machine is to be laid on one side Place a panel B on the hoisting system to 4 avoid damaging the machine With the help of an assistant tilt the machine on one side and lay it on the panel B 5 Remove the screws C then remove the wheels D and recov...

Page 94: ... 3 There is a short circuit in the drive system electronic board harness repair 4 The drive system electronic board is faulty replace 5 THE MACHINE DOES NOT MOVE Possible causes The battery voltage is too low charge the batteries 1 The drive paddle potentiometer is misadjusted or broken adjust or replace 2 The speed adjuster is broken replace 3 The drive system enabling microswitch is misadjusted ...

Page 95: ...e system electronic board Replace the drive system electronic board 7 Overcurrent output Check the drive system motor electrical input if the electrical input is normal replace the drive system electronic board 8 Missing power connection Check the drive system fuse and the drive system electronic board wiring harness if the fuse and the wiring harness are normal replace the drive system electronic...

Page 96: ... BA 531 BA 551 Turn off the switches 71 and 73 For CA 451 CA 531 CA 551 Disconnect the power supply cable 59 from the electrical mains For 4 CA 451 CA 531 CA 551 Open the recovery water tank cover 22 Remove the retaining plate 61 of the tank 40 Grasp the handle 41 and carefully lift the tank 40 5 Check 6 Tightening of mounting screws and nuts Correct position of fasteners Visible faults in the com...

Page 97: ...he ignition key 80 to 0 MACHINE WORKING HOUR CHECK For CA 451 CA 531 CA 551 equipped with optional hour counter Connect the power supply cable 59 to the electrical mains 1 Press the vacuum system switch 63 and read on the hour counter 79 the total number of working hours scrubbing drying 2 performed by the machine Turn off the vacuum system by pressing the switch 63 3 Disconnect the power supply c...

Page 98: ...Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor 2 For 3 BA 451D BA 531D BA 551D BA 551CD BA 611D Turn the ignition key 80 to 0 For BA 451 BA 531 BA 551 Turn off the switches 71 and 73 Disconnect the battery connector 12 4 Grasp the handle 41 and carefully lift the tank 40 5 Disconnect the cables A from the battery terminals 6 Remove the battery shims if present...

Page 99: ...d warning led 81c is flashing the machine is set to WET If the setting is to be changed perform the following procedure 2 Make sure that the switches 71 and 73 are turned off 3 Press and hold the switches 71 and 73 at the same time 4 Release the switches 71 and 73 at least 8 seconds after starting the machine 5 Within three seconds press the switch 73 again for a few seconds and check that the war...

Page 100: ...arning led 81c is flashing the machine is set to WET If the setting is to be changed perform the following procedure 2 Turn off the machine by turning the ignition key 80 to 0 3 Press and hold the switches 71 and 73 at the same time then turn the ignition key 80 to I 4 Release the switches 71 and 73 at least 8 seconds after starting the machine 5 Within three seconds press the switch 73 again for ...

Page 101: ...Remove the battery charger cable I if equipped from the cable holder J 3 Remove the screws A and carefully move aside the panel B by disengaging the grommet K from its housing on the panel 4 B Check replace the following fuses 5 C F1 fuse deck 40 A D F2 fuse vacuum system 30 A E F3 fuse drive system 30 A F F4 fuse signal circuits 3 A G F5 fuse brush pad holder release 20 A H F6 fuse pumps 3 A Only...

Page 102: ...551 Disconnect the power supply cable 59 from the electrical mains but do not place it on the holder 60 1 If the power supply cable 59 is on the holder 60 remove it 2 Move aside the recovery water drain hose 16 3 Remove the screws A and carefully move the panel B 4 Check replace the following fuse 5 C FL1 fuse electronic board 1 A Perform steps 2 to 4 in the reverse order 6 A A B A A C S301570 ...

Page 103: ... Remove the screws A and carefully move aside the panel B by disengaging the cable grommet C from its housing on the 4 panel B Disconnect the connectors D E F and remove the panel B 5 Disconnect the terminals G and H from the electromagnetic switch J Disconnect also the terminals I which are present 6 only on the models with drive system Remove the screws K and move the electrical panel L by disen...

Page 104: ...00 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 BRUSH MOTOR ELECTROMAGNETIC SWITCH DISASSEMBLY ASSEMBLY For BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D Continues L N J L K K M H G J I S301572 ...

Page 105: ...d from the cable holder 7 3 Remove the screws A and carefully move aside the panel B by disengaging the cable grommet C from its housing on the 4 panel B Disconnect the connectors D E F and remove the panel B 5 Disconnect the connectors G of the drive system electronic board H 6 Remove the screws I and move the electrical panel J by disengaging it from the lower fastener K 7 Remove the screws L on...

Page 106: ...104 909 6756 000 5 2010 03 BA 451 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 DRIVE SYSTEM ELECTRONIC BOARD DISASSEMBLY ASSEMBLY For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues L L J J I I H G G K S301574 ...

Page 107: ...nnector 12 1 Move aside the recovery water drain hose 16 2 Remove the battery charger cable 6 if equipped from the cable holder 7 3 Remove the screws A and carefully move aside the panel B by disengaging the cable grommet C from its housing on the 4 panel B Disconnect the connectors D E F and remove the panel B 5 On the panel remove the screws G then remove the function electronic board H 6 Assemb...

Page 108: ...on the holder 60 remove it 2 Move aside the recovery water drain hose 16 3 Remove the screws A and carefully move the panel B 4 If necessary mark the position of the connections C of the water flow control electronic board D to reinstall them correctly if 5 necessary refer to the wiring diagram to check the connection positions Disconnect the connectors C of the water flow control electronic board...

Page 109: ...harger a fault in the battery charger and relevant connections can affect the machine operation The battery charger is broken replace only for machine equipped with on board battery charger 3 There is an open in the fuses replace 4 The harness is cut pressed or short circuited repair 5 Error codes indicated by led 81a 81b 81c 6 Flashes Meaning Action Green yellow and red LED flashing simultaneousl...

Page 110: ...LAYOUT For BA 451 BA 531 BA 551 Key BAT 24 V battery C1 Battery connector C2 Battery charger connector CH Battery charger optional CS Deck connector EB1 Function electronic board ES1 Brush electromagnetic switches ES2 Vacuum system relay EV1 Water solenoid valve F1 Deck fuse F2 Vacuum system fuse F4 Signal circuit fuse HM Hour counter optional M1 Brush pad holder motor M2 Vacuum system motor NOTE ...

Page 111: ... Battery charger connector CH Battery charger optional CS Deck connector EB1 Function electronic board ES1 Brush electromagnetic switches ES2 Vacuum system relay EV1 Water solenoid valve F1 Deck fuse F2 Vacuum system fuse F4 Signal circuit fuse HM Hour counter optional M1 Brush pad holder motor M2 Vacuum system motor Colour codes BK Black BU Blue BN Brown GN Green GY Grey OG Orange PK Pink RD Red ...

Page 112: ...ion electronic board EB2 Drive system electronic board ES1 Brush electromagnetic switches ES2 Vacuum system relay EV1 Detergent solenoid valve optional F1 Deck fuse F2 Vacuum system fuse F3 Drive system fuse F4 Signal circuit fuse F5 Brush pad holder release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder motor M2 Vacuum system motor M3 Drive system motor M4 Water pu...

Page 113: ...1 BA 451D BA 531 BA 531D BA 551 BA 551D BA 551CD BA 611D CA 451 CA 531 CA 551 909 6756 000 5 2010 03 111 COMPONENT LAYOUT For BA 451D BA 531D BA 551D BA 551CD BA 611D Continues F4 F1 F2 ES2 ES1 C2 EB1 F5 F6 EB2 F3 CH CSC BAT M2 M4 M5 M3 M1 S301580 ...

Page 114: ...ergent solenoid valve optional F1 Deck fuse F2 Vacuum system fuse F3 Drive system fuse F4 Signal circuit fuse F5 Brush pad holder release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder motor M2 Vacuum system motor M3 Drive system motor M4 Water pump optional M5 Detergent pump optional RV1 Speed potentiometer RV2 Maximum speed potentiometer SW1 Drive system brush ena...

Page 115: ... FL1 EB1 HS C1 S301582 COMPONENT LAYOUT For CA 451 CA 531 CA 551 Key C1 Filtering condenser EB1 Water flow check electronic board EV1 Water solenoid valve FL1 Electronic board fuse FR Machine frame HM Hour counter optional HS Grounding screw M1 Brush pad holder motor M2 Vacuum system motor PL1 Plug SW1 Brush pad holder switch SW2 Vacuum system switch NOTE Figure showing CA 551 ...

Page 116: ...id valve FL1 Electronic board fuse FR Machine frame HM Hour counter optional HS Grounding screw M1 Brush pad holder motor M2 Vacuum system motor PL1 Plug SW1 Brush pad holder switch SW2 Vacuum system switch Colour codes BK Black BU Blue BN Brown GN Green GY Grey OG Orange PK Pink RD Red VT Violet WH White YE Yellow BN 1 YE GN BU 2 BN 1 BU 2 YE GN BU 2 YE GN BN 1 YE GN BU 2 BN 1 BU 2 BN 1 BU 2 BN 1...

Page 117: ...BAT 2 Ignition key circuit power supply IN OUT 24V always with connected batteries K1 3 Auxiliary signal power supply OUT 24V always with connected batteries SW1 SW2 4 Hour counter power supply OUT 0V with Vacuum function activated HM 5 Drive system electronic board enabling OUT 24V with key on I EB2 J1 15 6 Return from ignition key IN 24V with key on I K1 7 8 Electronic board power supply IN 0V a...

Page 118: ...ssed and brush function activated EV1 J3 MOLEX MINIFIT type 6 ways vertical only version CFBA706 PIN Description Electronic board in out V ref Connected to 1 Water pump power supply OUT 24V with key on I M4 only for CFBA706 2 Water pump power supply OUT 0V pulsed according to water flow setting only with paddle pressed and brush function activated M4 only for CFBA706 3 Solution pump power supply O...

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Page 120: ...ndards Nilfisk Advance SpA Registered office Via F Turati 16 18 20121 Milano Administrative office Strada Comunale della Braglia n 18 26862 Guardamiglio Lodi Phone 39 0377 451124 Fax 39 0377 51443 www nilfisk com ...

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