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Error Codes of Charger

The charger have an alarm system through successive flashes of the yellow LED.

Error code

Flash

Description

Battery not connected or reverse polarity or output short circuit.
Verify the battery connection.

Alarm time-out: damaged battery or battery capacity is too high
The alarm is reset disconnecting the main supply. If it persists consult your service.

Faulty battery charger
The alarm is reset disconnecting the main supply. If it persists consult your service.

Overtemperature
The alarm will be reset itself when the charger cools. Verify the ventilation.

Charger Cables Detail

1 Batteria -

2 Ba

1 Contatto COM Rel`

2 Contatto NC Rel`

Summary of Contents for 109070

Page 1: ...SERVICE MANUAL BMG Version AA Date May 9 2019 Document Number 10088000...

Page 2: ...trical system what to do if 17 2 2 Mechanical scrubbing system what to do if 19 2 3 Drying system what to do if 20 2 4 Frame and traction system what to do if 22 2 5 Solution delivery system what to d...

Page 3: ...it 80 7 1 Location on machine 80 7 2 Main Components 81 7 3 Lubrication Points 82 7 4 Work requirements 82 7 5 Operating mode 83 7 6 Related electrical circuit 84 7 7 Adjustments 86 7 8 Disassembly 86...

Page 4: ...Part I Product Introduction 4...

Page 5: ...ed by the floor The machine can be powered by 2 individual mono block 12V batteries to supply 24V DC to the motors and controls BMG is available in 2 models and 3 cleaning versions 56 PRO Version with...

Page 6: ...ed to this Manual 109070 BMG 2018 56 PRO 109073 BMG 2018 56 PLUS 109071 BMG 2018 65 PRO 109074 BMG 2018 65 PLUS 109072 BMG 2018 50 PRO 109076 BMG 2018 50 PLUS 1 3 The Serial Number Plate 1 Part Number...

Page 7: ...and tie long hair back Block the wheels before lifting the machine Lift the machine with equipment that can sustain the weight to be lifted Drain both tanks before transport Bring both the squeegee an...

Page 8: ...4 450 24 450 Maximum Ramp Gradient Transfer 1 18 18 18 Maximum forward speed Transport Default Km h mph 9 5 6 9 5 6 9 5 6 Vacuum Motor Voltage Nominal Power V W 36 650 36 650 36 650 Vacuum Motor Stage...

Page 9: ...n work conditions machine batteries water operator kg lb 1055 2326 1065 2348 1065 2348 Weight front wheel kg 171 235 lb 377 518 Front wheel pressure kg cm3 3 69 4 66 PSI 52 48 66 28 Weight rear right...

Page 10: ...1 7 1 BMG 56 10...

Page 11: ...1 7 2 BMG 65 11...

Page 12: ...1 7 3 BMG 50 BTO 12...

Page 13: ...0 50 1 Nm 37 lb ft 33 5 Nm 24 7 lb ft M12 84 8 Nm 62 5 lb ft 56 8 Nm 42 lb ft 1 10 Scheduled Maintenance Maintenance of Daily Weekly Monthly Yearly Charge batteries X Check Clean Tanks Hoses X Check C...

Page 14: ...overy Tank 8 Vacuum Group 2 Brush Deck Control 9 Solution Tank 3 Brush Deck 10 Squeegee Control 4 Front Carter Group 11 Squeegee 5 Electrical Harness 12 Braking Group 6 Display Card 13 Water Group 7 T...

Page 15: ...Proceed with on site adjustments brushdeck and Squeegee adjustment Check the functioning of the Optional if present Rear camera Anti collision sensors Front lights Service lights Wand Kit Gun Kit Onc...

Page 16: ...Part II Anomalies Resolution Guide 16...

Page 17: ...ion 2 1 at page 17 6 The machine is powered properly Check the battery charge level and if necessary perform a recharge cycle or replace it The machine has a very limited working autonomy 1 The BDI Ba...

Page 18: ...ires 7 The battery charger is not properly adjusted Adjust the battery charger properly see section 3 5 2 at page 39 8 The battery charger doesn t work Check the proper section see section 2 1 at page...

Page 19: ...tructions see sec tion 4 7 1 at page 62 10 The machine does not clean properly Verify use the brushdeck extra pressure control 11 The solution flow rate is not correct or not enough Refer to the prope...

Page 20: ...tch on Refer to the proper section see section 2 1 at page 17 3 The machine is not in working condition Switch on the machine Set the Wash Dry mode Press the traction pedal 4 The recovery tank is full...

Page 21: ...tions see section 3 4 1 at page 34 4 The vacuum motor carbon brushes are worn out Replace the vacuum motor carbon brushes 5 The vacuum motor is not working even if pow ered Replace the motor The sque...

Page 22: ...seat 5 The operator is sitting on the seat Check and or replace the seat see section 3 3 at page 27 6 The pedal is not pressed Press the pedal depending on the required speed 7 The pedal is pressed C...

Page 23: ...eces sary replace it see section 3 3 at page 27 8 FSS The water pump or the chemical pump doesn t work Check the pump connections and if necessary replace the non working one 9 The solenoid valve does...

Page 24: ...Part III Functional Groups 24...

Page 25: ...ormation from the micro switches and all the electronic devices of the machine These signals are translated from the main card to run correctly the scrubber dryer and to prevent any safety problem to...

Page 26: ...3 2 Location of Electrical Components 26...

Page 27: ...5 Spray Gun activation Switch 26 Rear Left Light 27 Rear Right Light 28 Front Left Light 29 Front Right Light 30 Solenoid Valve 31 SOS button 34 Electrobrake 35 Traction Pedal 38 Battery charger 40 Re...

Page 28: ...art of the machine and depending of the input information decides how to use the devices of the machine during normal work On the table here below is possible to identify the input output signals of t...

Page 29: ...oder 31 Brown Negative 2 Blink light 18 Red Positive 4 Encoder 31 White 5 Encoder 31 Yellow 6 Encoder 31 Brown Positive J5 2 Potentiometer 16 Brown Positive 3 Traction pedal micro 16 Gray Positive 4 P...

Page 30: ...le Solenoid Valve 15 Black Negative 7 Front Light 23 Green Negative 8 Chemical Pump Green Negative 9 Micro common Green Positive 10 Micro common 22 Red Positive 13 Solenoid Valve 15 Brown Positive 15...

Page 31: ...the whole machine 3 3 6 Extra pressure Lever The lever allows the switch see section 3 3 at page 27 to increase the pressure exerted on the central brushes With extra pressure activated a warning lig...

Page 32: ...st the back and neck 3 3 17 Reverse sensor Plus The reverse sensor see section 3 3 at page 27 positioned at the center of the rear bumper emits an intermittent acoustic signal that speeds up close to...

Page 33: ...cording to the voltage value of the batteries where Vb is the voltage read on the battery Display Vb Pb60 Gel60 Pure Lead Pb80 Gel80 100 24 3 24 3 24 5 24 3 24 3 90 24 3 24 3 24 5 24 3 24 3 80 24 1 24...

Page 34: ...ut disabled for this machine AL 6 General Keyboard Communication No communication between display and main board Check the connection between the cards If the problem persists replace the main card or...

Page 35: ...lem persists replace the main card AL 48 Function Overcurrent pump Pumps Short Circuit Check the connections if the problem per sists replace the main card AL 49 Function Brushes motor 1 Ammeter Overc...

Page 36: ...y of the actuator microswitches Check the connections and adjust the micros if the problem persists replace the actuator AL 68 Function Squeegee Actuator timeout Only with external limit switches if t...

Page 37: ...rcurrent of the Traction Motor AL 87 Traction Motor data reading Abnormal traction motor Output current Check the traction motor and its connections If the problem persists replace the main card AL 88...

Page 38: ...d the body of the microswitch Make sure the lever of the micro is working properly Otherwise proceed as follows Unscrew the fixing screws Move the microswitches using the loop adjustment Fix the screw...

Page 39: ...he charger follow the instructions Remove the charger from the machine Set up the internal dipswitches according to the following table The dipswitches are divided in two couples The higher couple are...

Page 40: ...m time out damaged battery or battery capacity is too high The alarm is reset disconnecting the main supply If it persists consult your service 3 Faulty battery charger The alarm is reset disconnectin...

Page 41: ...free access and to the parameter list protected by Password 3222 The structure of the menu can be shown in the following image The menu structure can be schematically summarized in the following image...

Page 42: ...button 5 With button 3 enter the third number of the password 2 and confirm with button 5 With button 3 enter the fourth number of the password 2 and confirm with button 5 To move inside of the menu...

Page 43: ...ind exit and confirm with key 5 The display will return to normal working mode but in the upper part it will be displayed the value of the selected parameter To exit form the Monitor Sets function tur...

Page 44: ...access to basic settings with free access and to the parameter list protected by Password 3222 The structure of the menu can be shown in the following image Turn on the machine and access the menus by...

Page 45: ...n ACTUATORS Access to the parameters of the actuators function TRACTION MENU Access to the parameters of the traction function DIGITAL INPUTS Factory parameters and settings ENG PARAMETERS Factory par...

Page 46: ...General Battery Traction off Level 0 0 100 Charge threshold beyond which the Traction Motor is inhibited General Battery Custom Level 5 5 V 23 5 15 0 40 0 Valid on Custom Battery Parameter Battery Lev...

Page 47: ...s Parameters Parameter Default Min Max Description General Access Mode Password 2 Dealer 3222 3000 3999 Dealer Password General Access Mode Password 3 Customer 2234 2000 2999 Customer Password General...

Page 48: ...O OFF YES ON General Config Solution Management None Dosing System enable None FSS FLR General Config Wand Yes No Yes Vacuum wand enable NO OFF YES ON General Config Spray gun Yes No Yes Solution gun...

Page 49: ...rush Motor Switch Off1 Delay sec 0 1 0 1 10 0 Brush Motor Switch off Delay when the traction pedal is released Brush Brush Motor Reset Delay sec 20 1 300 Reset Timing from amperometric protection Brus...

Page 50: ...etting of the First dispensing level Pump Water Pump level 2 40 0 100 Setting of the Second dispensing level Pump Water Pump level 3 60 0 100 Setting of the Third dispensing level Chemical Pump Parame...

Page 51: ...otor Switch On Delay sec 0 2 0 1 5 0 Brush Motor Switch on Delay when the traction pedal is pressed Vacuum Vac Motor Switch Off1 Delay sec 10 1 300 Off function Brush Motor Switch off Delay when the t...

Page 52: ...ith I Nom manages the amperometric protection alarm stop Actuator Actuator Squeegee Timeout sec 5 0 30 Max working time of the Squeegee Actuator Actuator Squeegee Overload Level Amp 5 0 2 0 10 0 Squee...

Page 53: ...to pass from forward way to reverse way and viceversa Traction Speed Sets Reverse Ramp 2 sec 2 0 0 3 5 0 In Working Mode Time to pass from forward way to reverse way and viceversa Traction Speed Sets...

Page 54: ...es the amperometric protection alarm stop brush mo tor Traction Motor Sets Overload Time sec 60 10 60 Traction motor Rated Timer with I Nom manages the amperometric protection alarm stop brush motor T...

Page 55: ...sity reading If the measured density is even lower an equalization cycle can be attempted if the charger allows it If in any case the measured density of all or some of the cells is less than the valu...

Page 56: ...ressive degeneration due to corrosion The drop in the electrolyte level is physiological in acid batteries so it is very important to periodically check the electrolyte level and possibly add water if...

Page 57: ...nder the machine body in a central position The washing unit control is assembled above it 4 2 Main Components 1 Brush Gearmotor 2 Bumper Wheel 3 Brush coupling Spring 4 Brush 5 Water Hose 6 Water Dis...

Page 58: ...g 20 Brush Deck lifting Pin 4 3 Lubrication Points For lubrication use standard grease Lifting Arms Bushings 4 4 Work requirements The washing unit only works if the following conditions are met 1 The...

Page 59: ...ump ON if water level is different than 0 24V to Pd Sitting Closed Backward function enabled during work Brushdeck Actuator goes down 24V to M4 Brush Motor ON 24V to M2 Solution Pump OFF Solenoid Valv...

Page 60: ...4 6 Related electrical circuit 4 6 1 BMG 56 60...

Page 61: ...8 ref to B Vb Vb Electrobrake Activated J2 1 ref to J2 2 Vb Vb Traction pedal pressed J5 3 ref to J5 6 Vb Vb Operator Seated J7 15 ref to J7 1 Vb Vb Brushes Actuator in motion J14 1 ref to J14 4 Vb Vb...

Page 62: ...n on the rear side This allows the brush to evenly lean to the ground and perform its function properly Procedure Remove the brush from the brush deck Insert a 3 5 mm spacer 0 2 in under the front par...

Page 63: ...chine Off Remove the batteries and disconnect the brush motor power connector A Release the compensation spring Unscrew the right and left screws B At the base of the gear disconnect the water flow tu...

Page 64: ...Disconnect the actuator connector and remove the batteries Then remove the seegers and the upper pin of the actuator B Then remove the seegers and the lower pin of the actuator C and remove it 64...

Page 65: ...d above it 5 2 Main Components 1 Right Brush Gearmotor 2 Right Splashguard Rubber 3 Right Splashguard Body 4 Right Brush uncoupling Pin 5 Adjustment Bushing 6 Brush Deck Body 7 Right Brush 8 Water Dis...

Page 66: ...26 Brush Deck lifting Pin 5 3 Lubrication Points For lubrication use standard grease Lifting Arms Bushing 5 4 Work requirements The 65 side brush unit only works if the following conditions are met 1...

Page 67: ...ump ON if water level is different than 0 24V to Pd Sitting Closed Backward function enabled during work Brushdeck Actuator goes down 24V to M4 Brush Motors ON 24V to M2a M2 Solution Pump OFF Solenoid...

Page 68: ...5 6 Related electrical circuit 5 6 1 BMG 65 68...

Page 69: ...J5 6 Vb Vb Operator Seated J7 15 ref to J7 1 Vb Vb Brushes Actuator in motion J14 1 ref to J14 4 Vb Vb J1 J2 J5 J7 J14 5 6 2 Relative electrical Components Brush Gearmotor The brush gear motor is a D...

Page 70: ...guards from the brush deck Lower the brush deck to the floor and turn off the machine Act on the hexagonal fixing screws A of the upper arms Tighten the fixing nut of the upper arms Check that the bub...

Page 71: ...urn off the machine Remove the water supply hose from the distributor A and unscrew the central support screw B Release the compensation spring remove the screw that holds the left arm to the brush de...

Page 72: ...5 8 3 Brush Deck Actuator see section 4 8 3 at page 63 72...

Page 73: ...ral position The orbital unit control is assembled above it 6 2 Main Components 1 Right Bumping wheel 2 Brush deck upper Body 3 Brush Motor 4 Brush deck lower Body 5 Left Bumping wheel 6 Antivibration...

Page 74: ...compensating Spring 25 Brush Deck lifting Pin 6 3 Lubrication Points For lubrication use standard grease Rotation Pin Actuator push Pin 6 4 Work requirements The sweeping unit only works if the follow...

Page 75: ...sed Dosing system enabled during work Chemical Pump ON if water level is different than 0 24V to Pd Sitting Closed Backward function enabled during work Brushdeck Actuator goes down 24V to M4 Brush Mo...

Page 76: ...6 6 Related electrical circuit 6 6 1 BMG 50 BTO 76...

Page 77: ...Traction pedal pressed J5 3 ref to J5 6 Vb Vb Operator Seated J7 15 ref to J7 1 Vb Vb Brushes Actuator in motion J14 1 ref to J14 4 Vb Vb Brushes Actuator ALL OUT J14 2 ref to J14 6 Vb Vb Brushes Act...

Page 78: ...d and perform its function properly Procedure Remove the Pad from the deck Lower the deck so that the pad rests evenly and parallel to the ground Check the flatness of the support surface with a bubbl...

Page 79: ...Lift the front of the machine with a suitable lifting system At this point remove the deck from the left side D 6 8 2 Brush Deck Actuator see section 4 8 3 at page 63 79...

Page 80: ...Chapter 7 Vacuum Unit 7 1 Location on machine The vacuum unit is located in central rear position 80...

Page 81: ...um Hose 16 Bumping wheel 17 Squeegee rear coupling 18 Wheel height adjustment knobs 19 Actuator 20 retaining Spring 21 Squeegee front coupling 22 Squeegee lifting Lever 23 Tilt adjustment knob 24 Sque...

Page 82: ...t only works if the following conditions are met 1 The batteries are not discharged 2 The operator is seated on the machine so as to press the seat safety switch 1 3 The machine is on 2 4 The electrob...

Page 83: ...d during work Vacuum motor OFF after 10 seconds at maxi mum level Sitting Closed Vacuum Disabled during work Squeegee Actuator rises 24V to M5 Vacuum Motor OFF after 10 seconds at maxi mum level VACUU...

Page 84: ...7 6 Related electrical circuit 84...

Page 85: ...J7 11 ref to J7 16 Vb Vb Seated Operator J7 15 ref to J7 1 Vb Vb Squeegee Actuator in motion J13 1 ref to J13 4 Vb Vb J1 J2 J5 J7 J13 7 6 1 Relative electrical Components Vacuum Motor The vacuum moto...

Page 86: ...5 degrees to the floor for its whole length To obtain the correct adjustment act on the squeegee wheels adjusting knobs A to adjust the distance from the floor and on the central adjusting knob B to a...

Page 87: ...elease the pressure spring E Remove the seeger to remove the pin and remove the front support 7 8 2 Squeegee Actuator Lower the squeegee and turn off the machine Remove the batteries and the battery t...

Page 88: ...Components 1 Backward switch 2 Key Switch 3 Horn 4 Steering Chain 5 Front Wheel 6 Max Pressure Switch 7 Handle Joint 8 Horn Relay 9 Battery Tray 10 Rear Wheel 11 Horn Button 12 Wand activation switch...

Page 89: ...on the machine so as to press the seat safety switch 1 3 The machine is on 2 4 The electrobrake is activated 5 The accelerator pedal is pressed 4 8 4 Operating mode TRACTION Operator Seat Microsw Acti...

Page 90: ...8 5 Related electrical circuit 90...

Page 91: ...to B Vb Vb Brake pedal pressed J5 3 ref to J5 6 Vb Vb Potentiometer Activated J5 2 ref to J5 4 Vb Vb Potentiometer Signal Activated J5 5 ref to J5 4 Vb Vb Curve Speed red Microswitch J7 6 ref to J7 1...

Page 92: ...until a medium tension of the chain is obtained which must not have any slack Tighten the locknuts and the lower screws 8 6 2 Steering Column Chain Remove the front carter Remove the display and the s...

Page 93: ...tor Remove the Complete Squeegee Holder see section 7 8 1 at page 86 Place a wedge at the front of the front wheel Lift the rear part of the machine with a suitable lifting system A and insert a shim...

Page 94: ...isconnect the two connectors E Remove the left wheel and the lower part of the relative bearing support F Unscrew the four screws G that fix the gearmotor to the ma chine frame extract the left axle s...

Page 95: ...e The Water unit is located under the machine body in central position 9 2 Main Components 1 Solution Tank 2 Chemical dosing Cap 3 Water fill Cap 4 Water Pump 5 Water Valve Knob 6 Water Filter 7 Pump...

Page 96: ...evel is different than 0 24V to Pa Solenoid Valve ON if water level is different than 0 24V to J6 13 to J6 5 Sitting Closed Dosing system enabled during work Chemical Pump ON if water level is differe...

Page 97: ...tank reserve floater enabled Recovery tank reserve floater disabled Forward pedal pressed Recycle Pump ON 24v ref to j7 2 j7 4 Sitting Closed Recovery tank reserve floater enabled Recycle Pump OFF 0V...

Page 98: ...9 5 Related electrical circuit 98...

Page 99: ...o J5 6 Vb Vb Backward activated J7 11 ref to J7 16 Vb Vb Seated Operator J7 15 ref to J7 1 Vb Vb FSS FLR activated J7 17 ref to J1 8 Vb Vb Solution Tank Floater J7 2 ref to J7 1 Vb Vb Water Pump Activ...

Page 100: ...9 mm Gray 22 in 0 035 in 436236 PAD HOLDER 535 mm 21 in Carbon Brushes 422462 BRUSH MOT CARB BR 7 x 14 x 19 mm 0 27 x 0 55 x 0 75 in BMG 65 PN Description Width Bristle Bristle Color 422189 BRUSH PPL...

Page 101: ...0 x 65 x 6 mm 35 x 2 5 x 0 25 in 228562 RUBBER KIT POLYURETHANE 890 x 65 x 6 mm 35 x 2 5 x 0 25 in 438487 WHEEL D 80 H 25 mm D 4 H 1 in Splashguards 228563 SPLASHG RUBBER R L PARA 40SH 475 x 100 x 6 m...

Page 102: ...SURE SWITCH 409491 EXTRAPRESSURE MICROSWITCH 216691 CURVE SPEED RED MICROSWITCH 443155 TRACTION PEDAL ASSEMBLY 226032 HORN SWITCH 443044 WAND SWITCH 443044 SPRAY GUN SWITCH 436434 BATTERY CHARGER OPTI...

Page 103: ...4 RECYCLE FILTER OPTIONAL 228377 RECYCLE FLOATER SWITCH OPTIONAL 10 2 4 Cleaning Solution Supply Unit PN Description 212616 CLEAN WATER COMPLETE FILTER 407887 COMPLETE SOLENOID VALVE 24V 1 2 ACL 3 223...

Page 104: ...Fimap S p A Service Manual BMG Fimap S p A Via Invalidi del Lavoro 1 37050 S Maria di Zevio Verona ITALY Tel 39 045 6060411 Fax 39 045 6060417 Edizione May 9 2019...

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