1. 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.

2. 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

3. 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

4. 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.

5. 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

6. 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)

7. 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.

8. 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).

9. Brush deck 3 different brush deck versions
BR brushes/pads – scrubbing width 660 mm
BR 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 BR 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.

10. 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.

11. 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 1800 rpm
Electrical input check:
4 to 6 A, at 24V (without load for each single motor)

12. 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.

13. 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

14. 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).

15. 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).

16. 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 amps at 24V
3 stage motor
SILENT MODE: board cut motor supply to 16V

17. 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.

18. 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 20Amps
Assembly instruction available for charger installation

19. 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
20 amps 2
4 GREEN blinks
GEL-AGM 3
4 YELLOW blinks
GEL, EXIDE type® 4
2 RED blinks
15 amps
(suggested for battery capacity < 160 Ah C5) 5
2 GREEN blinks 6
2 YELLOW blinks

20. 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

21. 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).

22. 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.

23. 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

24. 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

25. 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

26. 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

27. 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

28. Wiring diagram
(click to open)

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

30. End of presentation
QUESTION & COMMENTS?