MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 Technical Data Safety Instructions MODEL General BGS-250 Grinder Transport Initial Operation Operation Maintenance Electrical Systems Fault Diagnosis Spare Parts Grinding & Polishing Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 1 TECHNICAL DATA DECEMBER 2008 CONTENTS – SECTION 1 Rating Unit specifications Operative range and correct usage Stand-by power supply Machine type designation Grinding & Polishing...
Tool diameter 250 mm ø (~10 in.) Working width 250 mm (~10 in) Dust hose connection 50 mm ø (~2 in) Contact Diamatic for a suitable dust Recommended Dust Collector collector 230V Machines: Power consumption 2,2 kW 230V, 50 Hz for CEE-plug...
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Weight 154 lbs / 70 kg 1.3 OPERATIVE RANGE AND CORRECT USAGE The BGS-250 is exclusively designed to process horizontal surfaces. The machine must not be used for other purposes. The manufacturer will not be liable for damage resulting from incorrect usage.
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TECHNICAL DATA DECEMBER 2008 1.4 STAND-BY SUPPLY (GENERATOR) If the BGS-250 is to be operated using power from a generator, the generator must be operated in accordance with the current U. S. National Electric Code guidelines or European VDE standards, as appropriate (this applies, but is not limited to, the...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 CONTENTS – SECTION 2 Warnings and symbols Organizational measures Personnel selection and qualification Safety precautions applicable to different operating conditions Special work within the scope of use of the equipment and...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 2.1 WARNINGS AND SYMBOLS The following denominations and symbols are used in the Operating Instructions to highlight areas of particular importance: Symbol of operational safety. In these Operating Instructions this symbol will be...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 Indicates where consultation with the manufacturer is required. Instructions relating to periodic checks. Reference to important instructions contained in the Operating Instructions. 2.2 ORGANIZATIONAL MEASURES These Operating Instructions are to be kept with the machine, and...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 From time to time the working practices of the operators are to be checked by a supervisor, especially regarding awareness of safety and hazards. Operators must tie back long hair, and not wear loose clothing or jewelry including rings.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 2.3 PERSONNEL SELECTION AND QUALIFICATION Fundamental duties: Work on the machine may only be undertaken by trained personnel. Only trained personnel may be employed. Note the statutory minimum age.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 In the event of operational malfunctions the machine must be shut down immediately and secured. Secure the work area around the machine in public areas providing a safety distance of at least 6.5 feet (2 meters) from the machine.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 2.5 SPECIAL WORK WITHIN THE SCOPE OF USE OF THE EQUIPMENT AND MAINTENANCE ACTIVITIES AS WELL AS REPAIRS DURING OPERATION Mechanical servicing work: Put the machine in the Safety off position as described in Section 2.6 before carrying out any service work on the machine.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 Observe the local waste disposal regulations; in uncertain situations ask the next higher authority. Do not use any aggressive cleaning materials. Only use lint-free cleaning cloths. Always verify that any bolted connections that were loosened during service and maintenance work are properly secure and tight.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 2 SAFETY INSTRUCTIONS DECEMBER 2008 2.7 GENERAL SAFETY CO NSIDERATIONS Any machine, if it is not used according to regulations, may be hazardous during operation, set-up and servicing. The machine owner is responsible for compliance with the safety regulations...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 3 GENERAL DECEMBER 2008 CONTENTS – SECTION 3 Range of application Scope of supply Description of the machine Operating elements Electric components The tools Care and maintenance Grinding & Polishing...
SECTION 3 GENERAL DECEMBER 2008 3.1 RANGE OF APPLICATION Typical ranges of applications for the BGS-250 are for example: • To remove undulated concrete and asphalt surfaces • To prepare the surface for coatings • To remove coating defects • To remove residual mineral adhesives 3.2 SCOPE OF SUPPLY...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 3 GENERAL DECEMBER 2008 3.3 DESCRIPTION OF THE MACHINE 110V 50 Hz / 230V 50 Hz / 400V 50Hz Machines: Figure 3.3.1a Height adjusting handle Lifting handle Hand grip Coupling ON/OFF Emergency switch Flexible coupling...
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Gear Reducer (115V only) Lifting handle The Diamatic Grinding machine BGS-250 can reach an output of 2500 mm and distinguish itself with its high economic efficiency and easy handling. The machine levels when on uneven and undulated floors and therefore is also suitable for optimization of surfaces before blasting.
Hand wheel and mini leveler Figure 3.4.1 Before switching on the BGS-250, check that the cutter or diamond plate is in a horizontal position with the mini leveler (4). The adjusting can be done by turning the hand wheel (2) in the right or left direction.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 3 GENERAL DECEMBER 2008 3.5 ELECTRIC COMPONENTS The control box (3) is equipped with all control elements and instruments to monitor the grinding machine. ON Switch Pressing the "ON" push button switches on the driving motor. This occurs only when the power supply works properly.
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Choose the tool most appropriate for the surface to be treated. This will ensure optimal work output and wear for the BGS-250. The tools available are described below. You must use Diamatic/Blastrac grinding discs for your warranty to remain in effect. Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 3 GENERAL DECEMBER 2008 110V 50 Hz / 230V 50 Hz / 400V 50Hz Models Figure 3.6.2a Motor Adapter Adapter Disc Flex Coupling Tool (cutter plate shown) Cutter Plate (50Hz Machines only): − Remove deposit of dirt −...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 3 GENERAL DECEMBER 2008 115V 60 Hz Model: Figure 3.6.2b Motor Adapter Tooling plate Coupling Gear Reducer Adapter Disc Tool: 10” Diamond Grinding Disc (remove tooling plate (4) and attach grinding disc to the adapter disc (3).
Use of non-original replacement components or wear parts may void the machine warranty. Generally, the Diamatic BGS-250 requires very little attention regarding its maintenance. Verify that any wastes or fiber residues do not remain in the area of the grinding disc.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 4 TRANSPORT DECEMBER 2008 CONTENTS – SECTION 4 Unit specifications Manual mode of moving the machine Transport with cranes or lifts Transport of the machine with vehicle Operation of the machine while grinding Grinding & Polishing...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 4 TRANSPORT DECEMBER 2008 4.1 UNIT SPECIFICATIONS Model BGS 250 Dimensions in inches 46.4 x 20.5 x 45.3 Dimensions in mm 1180 x 520 x 1150 Weight 154 lbs / 70 kg 4.2 MANUAL MODE OF MOVING THE MACHINE To move the machine press down the handgrips (1) (see fig.4.3.1) of the...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 4 TRANSPORT DECEMBER 2008 4.3 TRANSPORT WITH CRANES OR LIFTS Figure 4.3.1a Figure 4.3.1b If the machine is to be transported by a crane or a fork lift, verify that the lifting strap(s) has sufficient capacity to support the weight of the machine (the gross weight is shown in Section 4.1 Unit specifications).
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 4 TRANSPORT DECEMBER 2008 4.4 TRANSPORT OF THE MACHINE WITH VEHICLE When transporting the machine in a vehicle, always drive carefully and in a manner to avoid the machine shifting. Secure the machine with a tightening load strap over the lower frame (2).
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 5 INITIAL OPERATION DECEMBER 2008 CONTENTS – SECTION 5 Preparation for initial operation Initial operation Grinding & Polishing...
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• Make sure the dust bin of the dust collector unit is empty. • Connect the electric cable of the dust collector with the supply. If problems with the BGS-250 arise during the assembly or start- up, call a qualified person for help. Work on electrical equipment may only be undertaken by qualified personnel .
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 5 INITIAL OPERATION DECEMBER 2008 5.2 INITIAL OPERATION Figure 5.2.1a: 110V 50 Hz / 230V 50 Hz / 400V 50Hz Figure 5.2.1b: 115V / 60Hz Use the following sequence to start the machine: • Be sure that the grinding disc or cutter plate is fixed.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 6 OPERATION DECEMBER 2008 CONTENTS – SECTION 6 Operation Switching-off the machine Trouble shooting Safety shutdown Restarting after a fault Proceedings- before and after a stationary period Grinding & Polishing...
Regular inspection is necessary to prevent unplanned down time of your grinding machine. See Section 7.2 Maintenance. Pay attention to the following aspects during operation of the Diamatic BGS-250. Before beginning the grinding work, verify that all bolted connections are properly secured and tight, especially those of the driving and handling devices.
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While using the dust collector, observe any special workers’ protection rules, and also the local regulations regarding waste The normal start up of the Diamatic BGS-250 for daily operation is the same as that described in Section 5.2 Initial Operation.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 6 OPERATION DECEMBER 2008 6.2 SWITCHING OFF THE MACHINE Figure 6.2.1 Use the following sequence to shut down the machine: • Press the red OFF switch (1) to switch off the motor. • Disconnect the extension cable from the socket and keep it in a safe place to secure the machine from unauthorized use.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 6 OPERATION DECEMBER 2008 6.3 TROUBLE SHUTDOWN In case of emergency or operating trouble, such as vibrations or loud noises, switch the machine off immediately by pushing the red OFF- button (1) on the power box.
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PERIOD Before a long stationary period If the Diamatic grinding machine will be out of action for a long period of time, preserve the equipment as described below: • Lay down the machine onto the steering handle so that the flexible coupling is not loaded.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 CONTENTS – SECTION 7 Recommendations Maintenance and inspection list Repairing Grinding disc replacement / assembly Machine maintenance The driving motor Other maintenance Influences on the grinding pattern Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 7.1 RECOMMENDATIONS Prior to any repair work on the machine and its drives, secure the machine against unintentional activation. Put the machine in its safety off position. Section 2.6 Failures due to inadequate or incorrect maintenance may generate very high repair costs and potentially long periods of down time for the machine.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 7.2 MAINTENANCE AND INSPECTION LIST Operating hours/time period Inspection points and maintenance instructions 12 hours after repairing Check all accessible screw connections for tightness. Every 100 hours Clean the grease zerk and add one pump of NLGI-2 grease to the gear box.
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7.3 REPAIRING As previously mentioned in Section 5.1 Initial operation, we recommend conducting initial repair work on the machine with the support of Diamatic personnel, by taking this advice, maintenance personnel get the opportunity to be trained by an expert on the machine.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 7.4 GRINDING DISC REPLACEMENT/ASSEMBLY Prior to any repair work on the machine and its drives, secure the machine against unintentional activation. Put the machine in the safety off position. See Section 2.6.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 Assembly Clean the adapter grinding disc thoroughly. Adjust the grinding disc in the centering. Set in and tighten the countersunk head screw. Remove the block and tilt the machine forward.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 7.5 MACHINE MAINTENANCE Disassembly: Step 1: Make sure that the power supply is disconnected from the electrical inlet. Remove switch from steering handle. Figure 7.5.1 Step 2: Remove clip (1) of the spindle and remove bolts (2).
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 Step 3: Remove bolts (1) and move the complete spindle out of the tube. Unscrew bolt (2) and remove the hand wheel. Remove clamping ring (4) and remove sleeve bearing (6) and shims (5). It’s important that no dust gets into the spindle (7).
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 Step 5: Now it’s possible to take out the wheel bracket (1). Remove star lock ring (2) and remove the wheel and washers (3). Use a new star lock ring when assembling the wheel again.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 Step 6 – 110V 50 Hz / 230V 50 Hz / 400V 50Hz Machines: Unscrew adapter plate (1) and remove spacer rings (2). Unscrew flexible coupling (3). Remove bolt (4). Remove the coupling (6) with a pulley puller.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 Step 6 – 115V 60Hz Machine: Unscrew adapter plate (1) and remove spacer rings (2). Unscrew flexible coupling (3) and remove spacer rings (4). Remove bolt (5). Remove the tooling adapter (6). When you do this: screw a 5/16-24 bolt into the gearbox shaft.
Keep the fan covering free and do not lay objects on the covering. In case of malfunction of the motor, please contact a skilled electrician. If the malfunction cannot be repaired, please contact Diamatic customer service toll-free at 800-256-3440. 7.7 OTHER MAINTENANCE Check the seals for wear, and replace them when they no longer provide a good seal against dust emissions from the machine.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 7 MAINTENANCE DECEMBER 2008 ________________________________________________________________ Notes ________________________________________________________________ Grinding & Polishing...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 CONTENTS – SECTION 8 Directions for electrical engineering Electric circuit diagram of E00587-1 230V/ 12.9A/ 50Hz Electric circuit diagram of E01521 230V/ 12.9A/ 60Hz Electric circuit diagram of E01532 110V/ 28.0A/ 50Hz...
To identify electrical components refer to the electrical schematics in Section 8, as appropriate, or call a Diamatic service center. The results of all electrical repair work must be verified using the appropriate measurement techniques per the regulations stated in the European VBG4 and VDE 0701 standards or per the applicable U.S.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 8.2 ELECTRIC CIRCUIT DIAGRAM – E00587-1 230V/ 12.9A/ 50HZ Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 8.3 ELECTRIC CIRCUIT DIAGRAM – E01521 230V/ 12.9A/ 60HZ Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 8.4 ELECTRIC CIRCUIT DIAGRAM – E01532 110V/ 28.0A/ 50HZ Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 8.5 ELECTRIC CIRCUIT DIAGRAM – E03951 400V/ 6.0A Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 8.6 ELECTRIC CIRCUIT DIAGRAM – 115V BGS-250 CONTROL PANEL FOR 120V/60Hz 13201 N. SANTA FE OKLAHOMA CITY, OK 73114 U.S.A. Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 8 ELECTRICAL SYSTEMS DECEMBER 2008 ITEM NUMBER DESCRIPTION P003743 MANUAL STARTER P003755 UNDERVOLTAGE TRIP P003741 SURFACE MOUNT ENCLOSURE P003740 MUSHROOM HEAD STOP BUTTON, TWIST RELEASE 5330005 12/3 CORD - 25' SECTION P003757 12/3 CORD - 5' SECTION...
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 9 FAULT DIAGNOSIS DECEMBER 2008 CONTENTS – SECTION 9 Fault diagnosis - grinding machine Fault diagnosis - electrical system Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 9 FAULT DIAGNOSIS DECEMBER 2008 9.1 FAULT DIAGNOSIS – GRINDING MACHINE Prior to any repair work on the machine or its drives, the machine must be secured against unintentional activation. Put the machine in its Safety off position. See section 2.6.
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 9 FAULT DIAGNOSIS DECEMBER 2008 9.2 FAULT DIAGNOSIS – ELECTRICAL SYSTEM Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by trained persons under the guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations.
MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 10 SPARE PARTS DECEMBER 2008 ITEM PART-NO. DESCRIPTION QTY. E03786 Hand wheel BE0093 M6 x 35 hex Socket head cap BE0094 Clamp adjusting ring BE0095 Shim Ø16x22x0.5 BE0098 Bolt M8x10 E03754 Spindle sleeve E03824...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 10 SPARE PARTS DECEMBER 2008 110V 50 Hz / 230V 50 Hz / 400V 50Hz: Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 10 SPARE PARTS JUNE 2007 110V 50 Hz / 230V 50 Hz / 400V 50Hz: ITEM PART-NO. DESCRIPTION QTY. E01493 BL Motor 230V / 50Hz (colour= blue) E01493 RD Motor 230V / 50Hz (colour=red)
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 10 SPARE PARTS JUNE 2007 115V 60 HZ: Grinding & Polishing...
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MODEL BGS-250 GRINDER OPERATING MANUAL SECTION 10 SPARE PARTS JUNE 2007 115V 60 HZ: ITEM PART-NO. DESCRIPTION QTY. P004621 Motor 115V / 60 Hz P004623 Gear reducer PG-10094 Adapter Plate with handle E03751 Base plate PG-10071 BSDP Adapter Plate E03759...
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SECTION 10 SPARE PARTS JUNE 2007 115V 60 Hz: Below is a listing of tooling options available for the BGS-250-115. These tools are not included with the machine when purchased. 10” Grinding Disc 1 EACH/MACHINE: CG-1020DB: 10" DIA. 20SEG GRINDING BLADE CG-1020DBBT: 10"...
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