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Blastrac bg-250g11 Manual

Gas powered concrete grinder
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BG-250G11 & BG-250G13
Gas Powered Concrete Grinder
Blastrac
6215 N. Aluma Valley Dr.
Oklahoma City, OK 73121
1-800-256-3440
© Copyright Blastrac
Revision (A) 12-23-04

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  • Page 1 BG-250G11 & BG-250G13 Gas Powered Concrete Grinder Blastrac 6215 N. Aluma Valley Dr. Oklahoma City, OK 73121 1-800-256-3440 © Copyright Blastrac Revision (A) 12-23-04...
  • Page 2 FORWARD ISPC/Blastrac is pleased that you have selected this Diamond Grinding System for your surface preparation requirements. This environmentally safe, closed- cycle, surface preparation machine has been designed and built for abrasive blast cleaning of horizontal surfaces. This manual has been prepared to assist the operator and the maintenance personnel in understanding the machine so that it may be operated in the most efficient manner and maintained in the best condition.
  • Page 3 Receipt of Machine Examine the shipment carefully for possible damage that might have occurred while in transit. If any damage is noted, notify the transportation carrier immediately and advise ISPC/Blastrac.
  • Page 4 This document is to be used as a guide in determining warranty policies and procedures for BLASTRAC products. It is to be used in determining whether a warranty is justified and also as a procedural guide in completing a BLASTRAC Warranty Claim form.
  • Page 5 Warranty Policy (Continued) Blastrac reserves the right to inspect and make the final decision on any merchandise returned under warranty. Blastrac offers no warranty with respect to accessories, including but not limited to, engines, motors, batteries, tires and any other parts not manufactured by us but which the original manufacturer warrants.

  • Page 6: Table Of Contents

    Grinding disc replacement / assembly ------------------------------------------------------------------ 44 Bearing Unit --------------------------------------------------------------------------------------------------- 45 Flexible coupling---------------------------------------------------------------------------------------------- 46 The V belt drive ----------------------------------------------------------------------------------------------- 47 The driving motor--------------------------------------------------------------------------------------------- 49 Additional maintenance ------------------------------------------------------------------------------------- 50 7.10 Spare parts ---------------------------------------------------------------------------------------------------- 50 7.11 Influences on the grinding pattern------------------------------------------------------------------------ 50 © Copyright Blastrac Revision (A) 12-23-04...
  • Page 7 For answers to your questions about this product, contact your local Distribution Representative or call: Blastrac 1-800-256-3440 or 1-405-478-3440 7 am – 6 pm, Mon-Fri (CST) Blastrac • 6215 Aluma Valley Dr. • Oklahoma City, OK 73121 USA © Copyright Blastrac Revision (A) 12-23-04...

  • Page 8: Rating

    Operating Instructions BG-250G11/G13 Technical Data November 2004 Contents Chapter 1 1.1 Rating 1.2 Unit specifications 1.3 Operating range and correct usage 1.4 Machine type designation 1.5 Advice for operators of the machine Copyright Blastrac Revision (A) 12-23-04...

  • Page 9: Rating

    Tool diameter 10 in (250 mm) Working width 10 in (250 mm) Dust hose connection 3 in (75 mm) Recommended Filter unit Blastrac® Turbo-Vac II, Blastrac 1-13DC Noise Level 78 DBA Vibration Level < 2,5 ms² Copyright Blastrac Revision (A) 12-23-04...
  • Page 10 Height 39.38 in (1000 mm) Weight 260/271 lbs (118/123 kg) 1.3 Operating range and correct usage The grinding machine BG-250G11/G13 is exclusively designed to grind horizontal surfaces. The machine used other purposes. manufacturer will not be liable for damage or injury resulting from such incorrect usage.
  • Page 11 Technical Data November 2004 1.5 Advice for operators of the machine When you use the grinding machine BG-250G11/G13 it is possible to exceed the allowed scale of sound level of 85 db(A). That sound level varies depending on the location. If the scale of sound level reaches 85 db(A) or more, the operators and the persons who work in the surroundings must wear noise protection.

  • Page 12: Chapter 2: Safety

    Operating Instructions BG-250G11/G13 Safety November 2004 Contents Chapter 2 2.1 Warnings and symbols 2.2 Organisational measures 2.3 Personnel selection and qualification 2.4 Safety precautions applicable to some operating sequences 2.5 Special work instructions 2.6 Definition of the Maintenance Mode 2.7 Possible dangerous aspects of the equipment 2.8 Electrical...
  • Page 13 Operating Instructions BG-250G11/G13 Safety November 2004 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 shown next to safety precautions that are to be taken in order to ensure prevention to life and injury.
  • Page 14 Operating Instructions BG-250G11/G13 Safety November 2004 Information, instructions and restrictions with regard to possible risks to persons or to extensive material damages. © Copyright Blastrac Revision (A) 12-23-04...
  • Page 15 Operating Instructions BG-250G11/G13 Safety November 2004 Warning against dangerous voltages. Indications relating to protective devices in electrical appliances. Indications where consultation with manufacturer is required. Instructions relating to periodic checks. Reference to important instructions contained in the Operating Instructions. ©...
  • Page 16 Operating Instructions BG-250G11/G13 Safety November 2004 2.2 Organisational measures The Operating Instructions are to be kept near the location where the machine is located and must be within reach at all times! In addition to the Operating Instructions, general and legal regulations regarding...

  • Page 17: Personnel Selection And Qualification

    Operating Instructions BG-250G11/G13 Safety November 2004 If safety-critical changes occur to the machine or its working method, the machine must be shut down immediately! The cause of the fault must be established immediately! Changes, add-ons or conversions to the machine which might impair...

  • Page 18: Safety Precautions Applicable To Some Operating Sequences

    Operating Instructions BG-250G11/G13 Safety November 2004 Define responsibilities of the machine operator also regarding to traffic safety regulations and empower him to decline instructions from third parties which are not complying with the safety requirements! Personnel being trained or made acquainted with the equipment may only be...

  • Page 19: Special Work Instructions

    Operating Instructions BG-250G11/G13 Safety November 2004 Carry out the switch on and off operations and pay attention to control display according to the operation manual! Before switching on the machine make sure that no-one can be endangered when the machine starts up!
  • Page 20 Operating Instructions BG-250G11/G13 Safety November 2004 Adjustment, servicing and inspection work and time limits specified in these Operating Instructions, as well as any information on the replacement of parts and equipment must be undertaken and/or complied with! These activities may only be undertaken by qualified personnel.

  • Page 21: Definition Of The Maintenance Mode

    Operating Instructions BG-250G11/G13 Safety November 2004 Make sure that electrical components used for replacement purposes comply with the original parts and are correctly adjusted if necessary. 2.6 Definition of the Maintenance Mode Definition: The machine is in a safe condition when it cannot generate any hazard.

  • Page 22: Possible Dangerous Aspects Of The Equipment

    Operating Instructions BG-250G11/G13 Safety November 2004 2.7 Possible dangerous aspects of the equipment Any machine, if it is not used according the regulations, may be hazardous for operating, setting-up and service personnel. The operating authority is responsible for compliance with the...

  • Page 23: Range Of Application

    Operating Instructions BG-250G11/G13 General November 2004 Contents Chapter 3 3.1 Range of application 3.2 Scope of supply 3.3 Description of the machine 3.4 Operating elements 3.5 The tools 3.6 Care and maintenance © Copyright Blastrac Revision (A) 12-23-04...

  • Page 24: Chapter 3: General 3.1 Range Of Application

    Honda Engine Manual One of the dust collectors that you have chosen for your machine ensures nearly dust free operation and also improvement of machine and tool life. Blastrac uses specially designed dust collection systems with high separation efficiency, thus extending the life of the machine components.
  • Page 25 Driving motor Brush seal (see Fig 3.4) The Blastrac grinding machine BG-250G11/G13 can produce a pattern of 10 inches (250 mm) and distinguishes itself by its high economic efficiency and easy handling. The machine levels uneven and undulating floors, therefore is also suitable for optimisation of surfaces before blasting.

  • Page 26: Operating Elements

    Handgrip and Jack Stand Operating lever Fig. 3.2 Before Switching on the BG-250G11/G13, the front part of the grinding machine must be lifted by pushing down on the handgrip (2) and pulling back on the jack stand operating lever (1). When the machine has started, retract the jack stand and slowly lower the disc to the work surface.
  • Page 27 Do not hold for more than three seconds while attempting to start. Holding on the start for long periods of time will damage the starter and drain the battery. See Honda Operating Manual for details concerning the operation of the Honda engine. © Copyright Blastrac Revision (A) 12-23-04...
  • Page 28 The throttle control may be pushed all the way forward to engage the choke and pulled all the way back to stop the engine. Cable may stretch over time requiring adjustment for correct operation. Push forward to increase engine speed and pull back to decrease engine speed. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 29: The Tools

    Operating Instructions BG-250G11/G13 General November 2004 3.5 The Tools Fig. 3.4 Brush seal Flexible-Coupling Diamond grinding disc Bearing-Unit Adapter Jack stand Spacer © Copyright Blastrac Revision (A) 12-23-04...

  • Page 30: Care And Maintenance

    Never operate the machine if you are unsure. Be sure the BG-250G11/G13 is clean and free of any debris before operating. Turn off the machine and check the cleanliness periodically and clean if necessary.

  • Page 31: Unit Specification

    Operating Instructions BG-250G11/G13 Transport November 2004 Contents Chapter 4 4.1 Unit specifications 4.2 Manual mode of moving the machine 4.3 Transport with cranes or lifts 4.4 Transport of the machine with vehicle © Copyright Blastrac Revision (A) 12-23-04...

  • Page 32: Chapter 4: Transport 4.1 Unit Specification

    Now you can move the machine to the new position. The machine will be transported after being separated into: • Grinding machine • Filter unit Turbo Vac II or 1-13 DC • General accessories © Copyright Blastrac Revision (A) 12-23-04...
  • Page 33 (2) Sling under wheel axle between wheel and chassis (3) sling under wheel axle between wheel and chassis on other side of machine Lift the load slowly and make sure it is stable before transporting. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 34: Transport Of The Machine With Vehicle

    Enclosed trailers or vehicles may be dangerous due to the gasoline present in the machine. Be aware of fumes that may exist in transport and storage. These fumes may present a fire hazard if exposed to extreme heat, spark or open flame. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 35: Chapter 5: Initial Operation

    Operating Instructions BG-250G11/G13 Initial Operation November 2004 Contents Chapter 5 5.1 Preparation for initial operation 5.2 Initial operation © Copyright Blastrac Revision (A) 12-23-04...

  • Page 36: Initial Operation

    The operator/owner is responsible for compliance with the safety regulations during operation and maintenance of safety devices supplied with the machine as well as the provision of appropriate additional safety devises. © Copyright Blastrac Revision (A) 12-23-04...
  • Page 37 Handgrip and Operating lever Fig. 5.1 Before Switching on the BG-250G11/G13, the front part of the grinding machine must be lifted by pushing down on the handgrip (2) and pulling back on the operating lever (1). Pulling back on the operating lever (1) will lower the jack stand and take the weight off the grinding disc.
  • Page 38 The engine will need to remain in the choke condition until it warms up. See the Honda Operating Manual for details concerning the operation of the Honda engine. © Copyright Blastrac Revision (A) 12-23-04...
  • Page 39 Pull throttle (3) all the way back or push E- stop (4). Key (5) on G13 may be turned to OFF to stop machine. Figure 5.4 © Copyright Blastrac Revision (A) 12-23-04...
  • Page 40 Operating Instructions BG-250G11/G13 Initial Operation November 2004 Notes © Copyright Blastrac Revision (A) 12-23-04...

  • Page 41: Switching-Off The Machine

    Operating Instructions BG-250G11/G13 Operation November 2004 Contents Chapter 6 6.1 Operation 6.2 Switching-off the machine 6.3 Emergency Shutdown 6.4 Safety shutdown 6.5 Restarting after a fault 6.6 Procedures after lengthy down time © Copyright Blastrac Revision (A) 12-23-04...

  • Page 42: Chapter 6: Operation 6.1 Operation

    A regular inspection is necessary to prevent downtimes of your grinding machine. See chapter 7 "Maintenance". Pay attention to following aspects during operation of the Blastrac Grinding machine BG250 G11/G13 • Before beginning daily grinding work, be sure all fasteners are tight and secure.
  • Page 43 Operating Instructions BG-250G11/G13 Operation November 2004 The normal start up of the Blastrac grinding machine BG-250G11/G13 in the daily operation does not differ from the described process in chapter 5.2 "Initial operation". Fig. 6.1 (Electric BG 250 shown) After connecting the suction tube to the air intake (2) of the machine, you can treat the surface as described in the following.
  • Page 44 CG-1020DBT These diamond grinding discs are specially designed to be use on the concrete surfaces. For questions about your application, please contact your local Blastrac representative. Some blades are available in a variety of segment harnesses. Segment hardness may be matched to specific jobs resulting in successful applications and improved diamond wear life.

  • Page 45: Emergency Shutdown

    Observe the "Maintenance Mode” condition, chapter 2.6. Read and understand the entire Blastrac Operating Instructions and Honda Engine Manual before operating or servicing this machine. Do not depend on individual chapters for all safety and operating procedures.

  • Page 46: Procedures After Lengthy Down Time

    6.6 Procedures after lengthy down time Steps before storage If the Blastrac grinding machine will be stored for a long period or time, follow the below steps: Rest the machine onto the jack stand so that the brush seals and the flexible coupling are not touching the floor.

  • Page 47: Chapter 7: Maintenance

    7.2 Maintenance and inspection list 7.3 Repairing 7.4 Grinding disc replacement / assembly 7.5 Bearing-Unit 7.6 Flexible coupling 7.7 The V-Belt drive 7.8 The driving motor 7.9 Additional maintenance 7.10 Spare parts 7.11 Influences on the grinding pattern © Copyright Blastrac Revision (A) 12-23-04...
  • Page 48 Our specialists will be happy to assist you with more advice. Follow additional operating and maintenance of OEM if included during your service and maintenance work. Pay attention to special notice given by instructions for electric-motors or combustion engines. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 49: Repairing

    • Check the tension of the V-belt, tension again if necessary. • Check the brush seal Quarterly • Lubricate the bearing-unit and the (Monthly) castor. • Replace the flexible coupling • Full overhaul and cleaning of the Annually complete machine. © Copyright Blastrac Revision (A) 12-23-04...
  • Page 50 Screws that have been removed must be replaced with those of the same quality (strength, material) and design. Prior to any repair works on the machine and its drives, secure the machine against unintentional starting. See chapter 2.6. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 51: Grinding Disc Replacement / Assembly

    Remove the block (2) and tilt the machine forwards. When replacing the grinding disc (4), also check the condition of the coupling and the grinding disc adapter (5). Always replace the worn screws (7). © Copyright Blastrac Revision (A) 12-23-04...

  • Page 52: Bearing Unit

    If grease continues coming out during the operation of the machine, the bearing unit must be overhauled or replaced. Do not use any low-grade grease. Low grade grease will overheat the bearing unit causing hot grease to escape and damage to the bearing unit. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 53: Flexible Coupling

    2 Unscrew the hexagonal head screws (7) and the nuts fitted at the bearing-unit (2). Check the conditions of the screws (4) and of the spacer tubes (6). Always replace all worn or damaged parts! © Copyright Blastrac Revision (A) 12-23-04...

  • Page 54: The V Belt Drive

    V-belt. Collection of dirt due to oil, grease or chemicals has to be avoided. In order to get perfect power transmission the V-belt drive has to be checked regularly. Fig. 7.4 (electric unit shown) © Copyright Blastrac Revision (A) 12-23-04...
  • Page 55 Light tighten the motor fastening screws. Stretch the belt tension with the straining screw at the upper side of the machine. (Note the max permissible tension according to Fig. 7.6). Tighten the motor fastening screws Screw on the cover. © Copyright Blastrac Revision (A) 12-23-04...

  • Page 56: The Driving Motor

    Keep the driving motor free from excessive dirt (Overheating). Keep the fan covering free and lay any object on the covering. In case of malfunction of the motor, please contact Blastrac. If the malfunction can not be repaired, please inform the Blastrac service center. © Copyright Blastrac...

  • Page 57: Additional Maintenance

    Apply oil on the adjusting pin of the jack stand operating lever and other moving parts oil in regular intervals. 7.10 Spare Blastrac recommends having the following spare parts on stock to avoid long down times. Part No. Description Qty.
  • Page 58 Operating Instructions BG-250G11/G13 Maintenance November 2004 Notes © Copyright Blastrac Revision (A) 12-23-04...
  • Page 59 Operating Instructions BG-250G11/G13 Electrical November 2004 Contents Chapter 8 8.1 Directions for electrical engineering 8.2 Electric circuits diagrams © Copyright Blastrac Revision A 12-23-04...

  • Page 60: Directions For Electrical Engineering

    Order the electric items with reference to the circuit diagrams in chapter 8.1 or call a Blastrac service centre. © Copyright Blastrac Revision A 12-23-04...
  • Page 61 Operating Instructions BG-250G11/G13 Electrical November 2004 8.2 Wiring Schematics BG 250G11 © Copyright Blastrac Revision A 12-23-04...
  • Page 63 Operating Instructions BG-250G11/G13 Electrical November 2004 BG 250G13 © Copyright Blastrac Revision A 12-23-04...

  • Page 65: Electrical Troubleshooting

    Operating Instructions BG-250G11/G13 Troubleshooting November 2004 Contents Chapter 9 9.1 Grinder troubleshooting 9.2 Electrical troubleshooting © Copyright Blastrac Revision (A) 12-23-04...

  • Page 66: Chapter 9: Troubleshooting 9.1 Grinder Troubleshooting

    Inappropriate grinding tool Replace the grinding tools by for the application appropriate grinding tools for the surface to be treated V-belt tension low Tension the V-belt © Copyright Blastrac Revision (A) 12-23-04...

  • Page 67: Troubleshooting

    “Maintenance Mode.” See Chapter 2.6 Fault Possible cause Remedy Motor does E-Stop depressed Pull out E-Stop not start Honda motor ON/OFF Turn switch to ON switch OFF Honda motor ON/OFF Turn switch to ON switch OFF © Copyright Blastrac Revision (A) 12-23-04...
  • Page 68 Operating Instructions BG-250G11/G13 Spare Parts November 2004 Contents Chapter 10 10.1 Spares Parts List BG250G11/G13 © Copyright Blastrac Revision (A) 12-23-04...
  • Page 69 Operating Instructions BG-250G11/G13 Spare Parts November 2004 © Copyright Blastrac Revision (A) 12-23-04...
  • Page 70 Pulley Drive Pulley P003651 V-Belt DG04 Cover B20509 Add On Weight **See Note Grinding Disc P003860 Flat Head Cap Screw DG60 Forkhead DG53 Bolt DG54 Bolt DG66 Spring ** See Chapter 6 for disc recommendations © Copyright Blastrac Revision (A) 12-23-04...
  • Page 71 DG64 Fingerhandle DG59 Adjusting pin DG58 Guide bolt DG50 Knee lever DG56 Pivot pin DG61 Fork head DG52 Lever P003661 Battery Bracket P003662 Front Battery Isulator P003663 Rear Battery Insulator P003663 Motor Mounting Plate © Copyright Blastrac Revision (A) 12-23-04...
  • Page 72 Operating Instructions BG-250G11/G13 Spare Parts November 2004 Notes © Copyright Blastrac Revision (A) 12-23-04...

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