Technical presentation Nilfisk BR 652/752 Welcome to the technical presentation on Nilfisk BR652, battery ride on scrubber. The aim of the training is to provide you with technical points of the machine.

Technical specifications BR 652 BR 752 BR 752C Cleaning width 650 mm 710 mm Squeegee width 890 mm Solution/clean water tank capacity 80 l Solution flow da 1 a 3 l/min. Vacuum system motor power 420 W Drive system motor power 300 W Maximum speed 6 km/h Standard batteries running time 2,5 - 3,5 h Total electrical consumption 60 A Brush motor power 2 x 400 W 2 x 600 W Brush speed 230 rpm 720 rpm Brushpressure with extra-pressure function OFF 30 kg 32 kg 35 kg Brushpressure with extra-pressure function ON 48 kg 50 kg  

Control Panel ECOFLEX Hour counter (When the machine is started) and solution level (While using the machine) Brush/pad-holder deck lifting/lowering switch and vacuum switch Ignition key Brush/pad-holder extra-pressure switch. With the cylindrical brush deck installed, this switch is disabled. Reverse gear switch Silent mode Squeegee lifting/lowering and vacuum system on/off switch Battery charge indicator Solution flow switch adjustment and level LED

Steering wheel New steering wheel integrate all working functions for easier operations: The membrane panel switch connected to the control board, all integrated into the steering wheel.

Drive system New drive unit Motor 300W @ 4200 rpm IP 44 Easy replaceable tire Motor electrical input check: 5 - 7 A at 24V without load and maximum forward speed

Speed Pedal New pedal Voltage modulation signal by HALL effect sensor No potentiometer = no adjustment required One only part = no serviceable component Higher reliability (over 10 million cycles)

Parking brake Electromagnetic brake on the top of the drive motor. Not used as speed brake but parking/stationary brake. The machine speed braking is given by the controller and can be adjusted (see program option on service manual) To move the machine with power off pull the lever or just insert a spacer to keep the lever pulled.

Drive system TROUBLESHOOTING THE MACHINE DOES NOT MOVE Possible causes: The motor brushes are worn (replace). The motor (M3) is malfunctioning (repair or replace). The under-seat microswitch is broken (replace). The pedal potentiometer (RV1) is broken (replace). The brake (BRK) is activated (deactivate). Function electronic board fuse (F2) open circuit (replace). Function electronic board (EB1) is faulty The function electronic board error codes indicate the drive system faults (see the Function Electronic Board Error Code paragraph).

Brush deck 3 different brush deck versions BR 652 2 brushes/pads – scrubbing width 660 mm BR 752 2 brushes/pads – scrubbing width 710 mm BR 752C 2 cyl. brushes – scrubbing width 710 mm The squeegee is the same size 890mm/35“ for BR 652 - BR 752 - BR 752C DISK and CYLINDIC deck are not interchangeable due to specific chassis with different deck support “Magic deck” is the unique feature of the brush deck which move to the inner of curve depending of the steering rotation. For a better drying even without the side splash guard.

Magic Deck Exploded view of the mechanical mechanism allow the deck support to move upon the drive unit rotation. In case deck impact, force is not transmitted back to steering thanks to release springs. Note when installing the driving wheel assembly and the deck support the gears must have arrows (J) aligned.

Brush motor DISC Motor 400W @ 2800 rpm IP40 Motor electrical input check: 3 to 4 A at 24V (without load for each single motor) Easy replaceable carbon brushes CYLINDRIC Motor 600W @ 1800 rpm Electrical input check: 4 to 6 A, at 24V (without load for each single motor)

Deck system TROUBLESHOOTING Function electronic board (EB1) is faulty (replace). Wiring harness between function electronic board (EB1) and brush motor electromagnetic switch (ES1) is damaged (repair). Electromagnetic switch (ES1) is damaged (replace). Fuse (F1) is open (replace). Carbon rushes are worn (replace). Motor (M1) is faulty (repair or replace). Actuator (M5) end-of-stroke microswitches are broken (replace the actuator). Actuator motor (M5) is broken (replace). See the Electrical System chapter, controller error codes.

Solution System / ECOFLEX Main component are located on the chassis under the solution tank and accessible from the rear of the machine Solution filter Solenoid valve Pump detergent

Solution System TROUBLESHOOTING Incorrect solution to the brushes, to check: The solution filter is clogged/dirty (clean). The solenoid valve (EV1) is broken or there is an open in the electrical connection (replace the solenoid valve/repair the electrical connection). There is debris in the solution/clean water tank clogging the output hole (clean the tank) and/or debris in the solution/clean water hoses clogging the flow (clean the hoses). The function electronic board (EB1) is faulty (replace). The display electronic board (EB2) is faulty (replace). The dashboard electronic board (EB3) is faulty (replace).

ECOFLEX TROUBLESHOOTING Incorrect solution to the brushes, to check: 6 items previous page 7. The function electronic board (EB1) is not set for the operation with EcoFlex™ system (remove the jumper wire (J4) in front of the electronic board). 8. The pump (M4) is broken (replace).

Recovery system Actuator no pre-adjustment needed. Squeegee cable raising has pulley mechanism to allow wider squeegee movement with shorter actuator travel. Note the correct cable layout for cable replacement VAC motor electrical consumption is 16 - 19 amps at 24V 3 stage motor SILENT MODE: board cut motor supply to 16V

Recovery system TROUBLESHOOTING Incorrect drying, to check: The vacuum motor M2 is faulty (check the electrical input). The vacuum motor carbon brushes are worn (replace). The wiring harness between function electronic board and vacuum system motor is damaged (repair). The function electronic board (ES1) is damaged (replace). The actuator squeegee (M6) is faulty (replace). The actuator fuse (F4) is open (replace). See the Electrical System chapter, function electronic board diagnosis.

Battery & onboard charger Key switch “ON” the display show the current machine setting and charging curve (if equipped with onboard charger OPT) 6 settings available: OPT on-board charger SPE 24V 20A high frequency IP 55 Fully controlled by machine electronics Factory standard setting #1 WET @ 20Amps Assembly instruction available for charger installation

Battery & charger curve selection If the setting is to be changed, perform the following procedure: a. Turn the key switch “OFF”. b. Press and hold the buttons “BRUSH “ and “VAC” at the same time, then turn the key switch “ON”. c. Continue to hold the buttons until the battery meter LED light turns “ON” and “OFF” and then release both buttons. d. Within 3 seconds, toggle the button “VAC” to select required charger setting (1 to 6 below): SETTING INDICATION BATTERY TYPE CHARGING CURRENT 1 4 RED blinks WET STANDARD @ 20 amps 2 4 GREEN blinks GEL-AGM 3 4 YELLOW blinks GEL, EXIDE type® 4 2 RED blinks REDUCED @ 15 amps (suggested for battery capacity < 160 Ah C5) 5 2 GREEN blinks 6 2 YELLOW blinks

Machine cut-off threshold Deep of discharge voltage approved for Exide battery: 21,6V GEL (= 1,8Vpc)  20,4V WET (= 1,7Vpc) correspond to brush motor stop and red led flashing

FUNCTION BOARD One only PCB integrate drive (include ESP sensor) and functions (motors, actuators, pressure sensor) (A - B) Power supply connection (+) and (-) (C - D) Drive motor connection (M1) and (M2). (E) Pressure switch module connection (J7A and J7B). (F) Electrical component wiring harness connection (J1). (G) Foot board wiring harness connection (J3). (H) Frame wiring harness connection (J2). (I) Vacuum system wiring harness connection (VA+ and VA-). (J) Recovery tank wiring harness connection (J6). (K) Electromagnetic brake wiring harness connection (J5). (L) Brush deck actuator wiring harness connection (J4).

FUSE lay out (F1) 50A fuse - Brush motors. (F2) 100A MIDI fuse - Function electronic board (drive and vacuum system). (F3) 3A blade fuse - Signal circuit. (F4) 15A blade fuse - Deck and squeegee lifting actuator. (ES1) brush motor electromagnetic switch.

Function board ERROR CODES Errors are shown on the display by “AL” +“XX” is the alarm code. The errors are repeated (in case of display malfunction) by the diagnostic LEDs (yellow and red) on the main board as following tables. General Alarms (YELLOW LED + RED LED FLASHING) Code = No. of flashes Meaning Condition Effect G2 EEPROM error Function block + Default setting reset G3 General thermal protection Heatsink temperature > 90 °C Function block G4 Blown F2 fuse V > 1V on F2 G5 Wrong KEY sequence Wrong key sequence G6 No signal from BATTERY CHARGER No signal from battery charger The charging battery phase is not shown G7 Undervoltage B+ - B- < THRESHOLD2 for t >10” G8 Serial communication error with dashboard electronic board No signal or decoding error No block G9 Battery voltage drop DeltaV (neg.)> 3V on battery voltage Drive system + electromagnetic brake block

Function board ERROR CODES Function Alarms (RED LED FLASHING) Code = No. of flashes Meaning Condition Effect F2 BRUSH motor amperometric protection Voltage higher than the safety threshold Brush electromagnetic switch output block F3 VACUUM SYSTEM amperometric protection Vacuum system abnormal electrical input > 30A for T>10s Vacuum system block F4 DECK ACTUATOR position irregularity End-of-stroke microswitch configuration not plausible or end-of-stroke not reached within 10” Deck actuator block F5 VACUUM SYSTEM power section damage CC MOSFET F6 PRESSURE SWITCH signal fault Pressure switch Vout > 4.0V Water level visualisation missing + water flow and % detergent management fault F7 VACUUM SYSTEM output short circuit I > 2 * 50A F8 Function general relay fault Always closed / opened Function block

Function board ERROR CODES Drive system alarms (YELLOW LED FLASHING) Code = No. of flashes Meaning Condition t2 Amperometric protection intervention I > rated current for t > protection time t3 Electromagnetic brake not present Res. J5.1-J5.2 > 1k t4 Pedal input activated by ignition J3.8 > DEADL on ascend. front J3.6 t5 Drive system power section damage CC MOSFET t6 Pedal input not admitted Res. J3.7-J3.9 > 10k or J3.8 > J3.7 t7 Overcurrent (motor D.C.) I > 1.5 * IMAX t8 Drive system relay fault Contacts always opened/closed

Function board ERROR CODES Other alarm indications on the display DISPLAY Meaning Condition “---“ Water level signal missing or not as specified Pressure switch module signal > 4.0V or floating “888” Serial communication problem between dashboard electronic board and function electronic board Signal missing or errors Off Dashboard electronic board power supply missing J1.1 – J1.4 < 12V

BLACK-BOX Handle programmer connect to port J9: Display the error codes, Display current values of setting, Change parameters, Show battery management data: Refer to service manual for details of programmer use and function modes GB-N Time of continuous use with discharged batteries GC Charging cycle interrupted before completion GD-N Charging phase duration ITALSEA UNIVERSAL PROGRAMMER, NILFISK P/N 9097297000

Wiring diagram (click to open)

Accessory Installation instructions (click to open) Ecoflex KIT Onboard charger KIT

End of presentation QUESTION & COMMENTS?