Diamatic BMGP-600, Manual

Page 1: ... INSTRUCTIONS 1 OPERATING MANUAL JANUARY 2008 Grinding Polishing MODEL BMGP 600 Grinder Technical Data 1 Safety Instructions 2 General 3 Transport 4 Initial Operation 5 Operation 6 Maintenance 7 Electrical Systems 8 Fault Diagnosis 9 Spare Parts and Tooling 10 ...

Page 2: ... SECTION 1 TECHNICAL DATA 1 OPERATING MANUAL DECEMBER 2008 Grinding Polishing 1 1 Rating 1 2 Unit specifications 1 3 Operative range and correct usage 1 4 Stand by power supply 1 5 Machine type designation CONTENTS SECTION 1 ...

Page 3: ...ensions BMGP 600 Length with handle extended 63 in 1600 mm Length with handle down 42 5 in 1080 mm Width 26 in 660 mm Height 47 5 in 1207 mm Weight 700 lbs 318 kg Diamatic US Diamatic BV 13201 North Santa Fe Utrechthaven 12 Oklahoma City OK 73114 3433 PN Nieuwegein United States of America THE NETHERLANDS Local 405 478 3440 T 31 0 30 601 88 66 toll free 800 256 3440 F 31 0 30 601 83 33 1 1 RATING ...

Page 4: ...317P 1 3 OPERATIVE RANGE AND CORRECT USAGE The BMGP 600 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 In these cases the user takes responsibility for all risks 1 4 STAND BY SUPPLY GENERATOR If the BMGP 600 may be operated using power from a generator the generator...

Page 5: ...MGP 600 GRINDER SECTION 1 TECHNICAL DATA 4 OPERATING MANUAL DECEMBER 2008 Grinding Polishing 1 5 MACHINE TYPE DESIGNATION Product Type POD Technology Working width in mm BMG P 600 Note POD Point Of Development ...

Page 6: ... 2 3 Personnel selection and qualification 2 4 Safety precautions applicable to some operating sequences 2 5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation 2 6 Definition of the safety off position 2 7 General Safety Considerations 2 8 Electrical engineering regulations CONTENTS SECTION 2 ...

Page 7: ...t to all safety precautions that are to be followed to maximize safety and equipment performance Follow these instructions and take special care in these circumstances In addition to these instructions the general safety precautions and accident prevention guidelines are also to be followed Particular details regarding the economical use of the equipment Information instructions and restrictions w...

Page 8: ...ng to particular working practices for example work organization work procedures and personnel safety Personnel entrusted with working with the machine must read and understand the Operating Instructions before starting work paying specific attention to the Safety information To read these instructions after work has commenced is too late This particularly applies to incidental activities such as ...

Page 9: ...ine Follow the OSHA and other applicable regulations for approved respiratory protection standards when operating this machine in a dry operation with a dust collector to avoid possible airborne contaminants Grinding and cutting concrete produces dust that may generate airborne respirable crystalline silica which can lead to silicosis and death Do not use in dry operation without an approved dust ...

Page 10: ...s Fundamental duties Work on the machine may only be undertaken by trained personnel Only trained personnel may be employed Note the statutory minimum age Clearly specify the responsibilities of personnel for operation setting up servicing and maintenance work Make sure that only authorized personnel operate or work on the machine Define responsibilities of the machine operator with regard to traf...

Page 11: ... the switch on and switch off operations in accordance with the operations manual Before turning on the machine verify that no one can be endangered when the machine starts up Do not turn off the dust collector while the machine is running Work on electrical equipment may only be performed by a skilled electrician or by trained persons under the supervision of a skilled electrician as well as in a...

Page 12: ...or explosive Keep children and visitors away from the work area at all times Refer to the MSDS of all substances in and around the machine and follow the appropriate safety guidelines associated with the use exposure of the substance Never pull machine by power cord run over cord with machine or forklift or pull on cord by extending machine distance from power source too far Connect power cord to ...

Page 13: ... it on Watch what you are doing Use common sense Do not operate machine when you are not fully alert Do not operate machine while under the influence of drugs alcohol or any medication Before any use of the machine check for damaged parts that should be replaced Check for alignment of moving parts binding of moving parts breakage of parts mounting of cutter on diamond tools and any other condition...

Page 14: ...aintenance manual frequently and use it to instruct others who may operate the machine Verify that the operator controls are working correctly Do not operate the machine if the operator controls are not working correctly Test the stop start and emergency stop controls each time you start the machine If your machine is equipped with a variable speed drive make sure the speed is set at its lowest sp...

Page 15: ...ve to be carried out according to the operation manual Methods for maintenance and repair If the equipment is switched off in order to carry out maintenance repair or adjustment it must be secured against unintended restart Switch OFF and disconnect the machine from the power supply See Section 2 6 Safety off position for specific details Always dispose of the contents of the dust bin or of a conn...

Page 16: ...r if being used Waiting for all drives to stop Disconnect from power source Securing against unintended restart Work on electrical equipment may only be performed by a skilled electrician or by trained persons under the supervision of a skilled electrician as well as in accordance with the local electrical engineering regulations 2 6 DEFINITION OF THE SAFETY OFF POSITION 2 7 GENERAL SAFETY CONSIDE...

Page 17: ...en troubleshooting From time to time check multi meters to ensure that they are operating correctly Before connecting machine to a power source be sure the voltage supplied is the same as that specified on the nameplate of the machine or motor A power source with voltage greater than that specified for the machine can result in serious injury to the user and damage to the machine If in doubt do no...

Page 18: ...ting the machine When using an extension cord be sure to use a cord heavy enough to carry the current the machine will draw An undersized cord will cause a drop in line voltage resulting in loss of power and overheating See Section 3 0 for the table showing the correct size and type of conductor to use depending on cord length and nameplate ampere rating If in doubt use the next heavier gauge As t...

Page 19: ...AL 18 Grinding Polishing OPERATING MANUAL DECEMBER 2008 3 1 Range of application 3 2 Scope of supply 3 3 Description of the machine 3 4 Operating elements 3 5 Electric components 3 6 Driving part 3 7 Care and maintenance CONTENTS SECTION 3 ...

Page 20: ...lue In addition the machine is capable of leveling uneven and undulating floors This includes the optimization of surfaces concrete polishing wood sanding and removing tiger striping after shot blasting Depending on the application the diamond disc holder can be fitted with several different types of diamond grinding discs Scope of supply of the machine Grinding machine BMGP 600 Operating manual 1...

Page 21: ...ng weights located on both sides of the motor that allow the user to adjust the head pressure by rotating them forward or backward An operator control panel is placed within operator reach that is designed to include the basic machine controls as well as a dead man lanyard for safety 3 3 DESCRIPTION OF THE MACHINE Rotating weight 3 on each side Operator Control Panel Electrical Box 7 5HP motor Dus...

Page 22: ...d with a rubber skirt allowing the machine to maintain a seal on uneven surfaces The swing handle may be adjusted down for transport and or tight spaces Two sets of vacuum ports are provided so that the machine may be used with or without the POD technology For example when using a slicer kit the lower vacuum port should be used Swing Handle POD Vacuum Port Vacuum Port for non POD applications ...

Page 23: ... for anti wear protection with no maintenance necessary Although care should be taken to keep the gear box sealed to prevent contaminants from entering The shafts are designed with shoulders to establish fixed installation locations to help ensure an even grind However it is the responsibility of the operator to maintain the equipment and select the appropriate tools for the job Bearings are locat...

Page 24: ...slice coatings and adhesives apart and the diamond plugs can be used to clean off any remaining material to remove hard brittle coatings and paints or to prepare concrete surfaces for coating Due to the POD functionality the BMGP 600 does not require a water source for cooling the tooling or reducing dust while grinding The revolutionary POD technology cools the diamond segments on the tooling as ...

Page 25: ...Amp 25 ft 12 3 BMGP 600 208V and BDC 1324 110V 32 Amp 208V 19 Amp 120V 50 Amp 208V 20 Amp 120V See Above See Above BMGP 600 230V and BDC 1324 110V 29 5 Amp 230V 19 Amp 120V 50 Amp 220V 20 Amp 120V See Above See Above BMGP 600 208V and 317P 208V 50 Amp 60 Amp See Above See Above BMGP 600 230V and 317P 230V 47 5 Amp 60 Amp See Above See Above Machine is supplied with 55 ft of power cord with no elec...

Page 26: ... the safety of the personnel working on it Stop button The red button will stop the machine Start button By pressing the green button the motor will start Emergency Stop E Stop When pressed the machine will stop The E stop must be reset by twisting to restart the machine Safety Lanyard When the lanyard is pulled from the switch it will stop the machine The lanyard must be reconnected into the swit...

Page 27: ...2 for the recommended maintenance schedule Before using the machine you should always verify that all bolted connections are secure and tight Do not clean plastic parts or machine with solvent Solvents such as gasoline thinner benzene carbon tetrachloride and alcohol may damage and crack plastic parts handle grips electric cords as well as damage painted surfaces of the machine Clean plastic parts...

Page 28: ... GRINDER SECTION 3 GENERAL 27 Grinding Polishing OPERATING MANUAL DECEMBER 2008 ________________________________________________________________ Notes ________________________________________________________________ ...

Page 29: ...TION 4 TRANSPORT 28 Grinding Polishing OPERATING MANUAL DECEMBER 2008 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 CONTENTS SECTION 4 ...

Page 30: ...ight 47 5 in 1207 mm Weight 700 lbs 318 kg To move the machine press down the handgrips of the machine until the front part rises approximately 4 inches 10 cm from the ground It can now be pushed around on its wheels The machine should only be moved around after the attachments are disconnected such as Generator if being used Dust collection unit 4 1 UNIT SPECIFICATIONS 4 2 MANUAL MODE OF MOVING T...

Page 31: ...of the motor Route the strap behind the motor and through the opposite rear weight rest Make sure that you run the strap under the motor mounting plate so as not to put stress on the motor mounting plate bolts Ensure that you clear the electrical cables hoses etc Feed a second strap through the middle weight handle to keep the machine from tipping forward when lifting These lifting locations are a...

Page 32: ...s drive carefully and in a manner to avoid the machine shifting Secure the machine with a tightening load strap over the lower frame location 1 Place another strap through both middle weight handles and tighten location 2 Tighten down with the load straps to the body of the vehicle 4 4 TRANSPORT OF THE MACHINE WITH VEHICLE Location 1 Location 2 ...

Page 33: ...MODEL BMGP 600 GRINDER SECTION 5 INITIAL OPERATION 32 Grinding Polishing OPERATING MANUAL DECEMBER 2008 5 1 Preparation for initial operation 5 2 Initial operation CONTENTS SECTION 5 ...

Page 34: ...al damage Check the dust hose for damage Connect the grinding machine and the dust collector unit with the flexible dust hose Make sure the dust bin of the dust collector unit is empty Before start up all operating personnel must be familiar with the safety regulations given in this manual If problems with the BMGP 600 arise during the start up call a qualified person for help Work on electrical e...

Page 35: ... changeover instructions and Section 10 for available tooling options Use the following sequence to start the machine Switching on the grinding machine Press down on the handle to raise the tooling off the floor Push the green start button on the operator control panel Move the machine slowly side to side in a sweeping motion or forward and reverse depending on the work space Switching off the gri...

Page 36: ...DER SECTION 5 INITIAL OPERATION 35 Grinding Polishing OPERATING MANUAL DECEMBER 2008 ________________________________________________________________ Notes ________________________________________________________________ ...

Page 37: ...ION 36 Grinding Polishing OPERATING MANUAL DECEMBER 2008 6 1 Pre startup Inspections 6 2 Operation 6 3 Trouble shooting 6 4 Safety shutdown 6 5 Restarting after a fault 6 6 Proceedings before and after a stationary period CONTENTS SECTION 6 ...

Page 38: ...nes cloths or standing liquid on the surface Any obstructions in the surface to be treated like concrete reinforcing steel or other objects should be removed from the work surface to prevent damage to the machine and tooling 6 1 PRE STARTUP INSPECTIONS These Operating Instructions are to be kept with the machine and must be within reach at all times Only trained personnel may be employed Note the ...

Page 39: ...ing Polishing OPERATING MANUAL DECEMBER 2008 Verify that the electric cable and dust hose are clear from vehicle traffic such as forklifts and other equipment If there are doubts as to how to start up the machine read Sections 5 of this operating manual ...

Page 40: ...n instructions are followed Turn on the dust collector before operating the Diamatic BMGP 600 and ensure the required respiratory protection is being worn Turn the dust collector on and make sure all of the hose connections are secure Make sure the machine is fully contacting the floor and none of the tools are dislodged from their holders Hold on to the handle of the machine with one hand and wit...

Page 41: ...acity and even coverage of the work area as shown below Figure 6 1 Movement of Machine Looking down through the top of the machine If the machine is left running on one area of the floor too long it will create a depression in the surface This result is usually not desired and may require corrective repairs to those areas The Diamatic BMGP 600 has a unique floating head coupling system that follow...

Page 42: ...diamond plugs and the POD rotating shroud and seals Blockages or loss of seal in the dust collection path will result in poor removal of dust and an increased exposure to airborne dust If an inadequate dust collection system is used with the BMGP 600 the machine will also perform poorly If non POD tooling is used with this machine the POD process will not work correctly and also cause poor dust co...

Page 43: ...150 PCD or 25 30 8 seg 1000 3000 MEDIUM COARSE Epoxy Less than 10 Mil 300 25 30 or 50 60 B seg 1000 4000 MEDIUM Epoxy 10 20 Mils 200 PCD or 25 30 8 seg 1000 3000 MEDIUM COARSE Epoxy 1 8 to 1 4 Top 25 75 PCD or 25 30 8 seg 200 800 COARSE Grinding epoxy mortar 400 25 30 or 50 60 B seg 1000 2000 MEDIUM Carpet mastic 400 PCD or 25 30 8 seg 1000 2000 MEDIUM COARSE Table 6 1 Performance Chart The produc...

Page 44: ... or operating trouble such as vibrations or loud noises switch the machine off immediately by pushing the OFF button E stop or pull the lanyard on the operator control panel 6 4 SAFETY SHUTDOWN Before performing inspection or maintenance work make sure that all moving machine parts are stopped Observe the Safety off position Section 2 6 6 5 RESTARTING AFTER A FAULT The results of all electrical re...

Page 45: ...ieve pressure from tooling plates Store the machine in a dry and secure location Keep machine out of the reach of children or unqualified operators After a long stationary period Check all belts for proper tension and re tension as necessary See section 7 for instructions Check bearings for proper rotation and fluid motion Re lubricate if necessary by adding grease via the grease zert on the beari...

Page 46: ...GRINDER SECTION 6 OPERATION 45 Grinding Polishing OPERATING MANUAL DECEMBER 2008 ________________________________________________________________ Notes ________________________________________________________________ ...

Page 47: ...GRINDER SECTION 7 MAINTENANCE 46 Grinding Polishing OPERATING MANUAL DECEMBER 2008 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 Tooling Changeover 7 5 Other maintenance CONTENTS SECTION 7 ...

Page 48: ...is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a year Due to different working conditions inspection and maintenance intervals may vary Prepare a suitable inspection schedule considering known working conditions and experience If you have any questions please contact your Diamatic Customer Support at 1 800 256 34...

Page 49: ...orking correctly Check the power supply cable for damage Check the dust collector hose for damage Check tooling plates and remove any foreign material and debris Check the tooling for wear Check the tension of the V belt adjust as is required Check the rubber dust seal After each use Check the V seal ring for damage Check the wear ring for groove depth It should be flipped when the groove is 1 8 d...

Page 50: ...laced the following sequence of maintenance must be followed It is advisable to stock all spare or wear parts that cannot be obtained quickly As a rule production standstill periods are more expensive than the cost for carrying the corresponding spare part Screws or bolts that have been removed must be replaced with those of the same quality strength material and design 7 3 REPAIRING Prior to any ...

Page 51: ...ck so that the handle rests on the ground and tooling is exposed 5 Make sure the machine is secure and cannot fall back on the head 6 Using a hammer hit the bottom of the tooling plates to dislodge the tools from the plate 7 The tools should fall out Plug Installation 8 Clean out the tooling holes to remove remaining dust 9 If replacing the tooling with used plugs notice the add photo tail and ins...

Page 52: ...ou may flip them over and use the other side before replacement It is recommended that you place an order for replacements when you do flip to use the second side Note If the grooves are too deep you should notice a decrease in your dust collection performance Clean the machine with a damp cloth 7 5 OTHER MAINTENANCE Do not use high pressure water for cleaning the machine Use of non original repla...

Page 53: ...ECTION 8 ELECTRICAL SYSTEMS 52 Grinding Polishing OPERATING MANUAL DECEMBER 2008 8 1 Directions for electrical engineering 8 2 Electrical schematic 8 3 Electrical box layout 8 4 Electrical component listing CONTENTS SECTION 8 ...

Page 54: ...CTRICAL ENGINEERING Work on electrical equipment or operating materials may only be performed 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 The results of all electrical repair work must be verified using the appropriate measurement techniques per the applicable U S gui...

Page 55: ...MODEL BMGP 600 GRINDER SECTION 8 ELECTRICAL SYSTEMS 54 Grinding Polishing OPERATING MANUAL DECEMBER 2008 8 2 ELECTRICAL SCHEMATIC ...

Page 56: ...MODEL BMGP 600 GRINDER SECTION 8 ELECTRICAL SYSTEMS 55 Grinding Polishing OPERATING MANUAL DECEMBER 2008 8 3 ELECTRICAL BOX LAYOUT ...

Page 57: ...5003 SWITCH 9 1 P005005 SWITCH 10 1 P004587 ENCLOSURE 11 1 P004588 ALUMINUM BACKPANEL FOR ENCLOSURE 12 1 P004248 ENCLOSURE 13 3 P001046 CONNECTOR 3 4 STRAIGHT 14 3 P001041 CONDUIT FLEX 3 4 15 1 P001047 CONNECTOR 3 4 90 DEG ELBOW 16 2 P002208 CONNECTOR 1 2 90 DEG ELBOW 17 1 P004790 SAFETY SWITCH DEADMAN WITH CORD GRIP 18 1 P004791 SAFETY SWITCH DEADMAN KEY W TETHER AND CLIP 19 1 P004568 CORD GRIP w...

Page 58: ...MODEL BMGP 600 GRINDER SECTION 9 FAULT DIAGNOSIS 57 OPERATING MANUAL DECEMBER 2008 Grinding Polishing 9 1 Troubleshooting grinding machine 9 2 Troubleshooting electrical system CONTENTS SECTION 9 ...

Page 59: ...k the bearing on the axle drive shaft and replace if necessary Check the tension of the drive belt replace if necessary Change the motor Reduced or no grinding performance Grinding tools have reached the maximum permissible wear Inappropriate grinding tool for the application Too low tension of the drive belt Replace the worn parts Replace the grinding tools with appropriate grinding tools for the...

Page 60: ...ged or obstructed Hose not properly connected Dust collector filters are saturated with dust POD rotating shroud hoses have become damaged or disconnected Replace diamond tooling Replace seal Dump the dust bin Inspect hose and replace if necessary Ensure securely attached Clean or replace as necessary Replace or reconnect as appropriate Machine pulls to one side Improperly matched diamond tooling ...

Page 61: ... or under voltage condition Motor defective Lanyard pulled out Reduce additional load or increase extension cord wire size Check extension cord size verify proper connection to power source Have motor checked by a trained professional to confirm Check the lanyard connection 9 2 TROUBLESHOOTING ELECTRICAL SYSTEM Work on electrical equipment or operating materials may only be performed by a skilled ...

Page 62: ...NDER SECTION 9 FAULT DIAGNOSIS 61 OPERATING MANUAL DECEMBER 2008 Grinding Polishing ________________________________________________________________ Notes ________________________________________________________________ ...

Page 63: ...MODEL BMGP 600 GRINDER SECTION 10 SPARE PARTS AND TOOLING 62 OPERATING MANUAL DECEMBER 2008 Grinding Polishing 10 1 Spares Parts BMGP 600 10 2 Tooling Available BMGP 600 CONTENTS SECTION 10 ...

Page 64: ...MODEL BMGP 600 GRINDER SECTION 10 SPARE PARTS AND TOOLING 63 OPERATING MANUAL DECEMBER 2008 Grinding Polishing 10 1 SPARE PARTS BMGP 600 ...

Page 65: ...IVE 1 14 6150020 SHEAVE 2 15 PG 10153 WELD BELT GUARD 1 16 PG 10135 WELD AIR PLENUM 1 17 CP 10118 OIL SEAL 1 25 2 18 PA 10426 PLATE SEAL RETAINER 2 19 PA 10667 SHAFT HEAD 2 20 CP 10119 SHOULDER BOLT 1 2 X 5 8 2 21 PA 10683 LINKAGE TUBE 1 22 P004451 SHOULDER BOLT 3 8 X 1 1 2 1 23 PA 10678 PL MAIN SHROUD 1 24 PG 10294 SHROUD WELDMENT 1 25 CP 10126 QUICK RELEASE PIN 1 2 X 5 2 26 PG 10164 WELDMENT WEI...

Page 66: ...X 3 1 2 LONG 1 47 P004449 BOLT 1 2 X 3 SHOULDER 2 48 CP 10127 V BELT 3VX 400 2 49 CP 10254 SEAL ROTARY SHAFT RING 2 1 4 SHAFT DIA 2 50 P004427 P CRUSHPROOF TUBE 1 DIA X 3 LENGTH 6 51 P004438 HOSE FLEX 2 ID 27 LONG BLACK 2 52 P004628 BUSHING TRANTORQUE 3 4 1 53 P004512 2 VELCRO ADHESIVE BACKED HOOK 1 54 P004492 HOUSING SEAL NATURAL GUM RUBBER 1 55 PA 10890 CAP ROUND VINYL 2 I D 2 HEIGHT 2 56 CP 102...

Page 67: ...MODEL BMGP 600 GRINDER SECTION 10 SPARE PARTS AND TOOLING 66 OPERATING MANUAL DECEMBER 2008 Grinding Polishing ...

Page 68: ...0135 WELD AIR PLENUM 1 10 CP 10118 OIL SEAL 1 25 2 11 PA 10426 PLATE SEAL RETAINER 2 12 PA 10667 SHAFT HEAD 2 13 PA 10831 SHROUD ALUMINUM POD 2 14 2055710 BEARING 2B FLG 3 4 2 15 PA 10860 WEAR RING V SEAL 2 16 CP 10146 SEAL V RING 2 17 PA 10861 RETAINER V SEAL 2 18 PG 10156 TOOL HOLDER WELDMENT 2 19 PA 10859 ALUM DUST TUBE SHROUD 6 20 CP 10254 SEAL ROTARY SHAFT RING 2 1 4 SHAFT DIA 2 21 P004427 P ...

Page 69: ...S PLUG 3 5 SEG POD BLUE SOFT BOND DP3 POD82530 PLUG 3 8 SEG POD DIAMOND 25 30 GRIT DP25 BSDPOD2530 PLUG 2 5 6 SEG BEVELED 25 30 GRIT DP25 BSDPOD5060 PLUG 2 5 6 SEG BEVELED 50 60 GRIT DP25 BSDPOD80100 PLUG 2 5 6 SEG BEVELED 80 100 GRIT DP25 BSDPOD140170 PLUG 2 5 6 SEG BEVELED 140 170 GRIT RESINS BG200401 P CONCRETE RESINS MIXBOND BLACK 100 BG200402 P CONCRETE RESINS MIXBOND BLUE 200 BG200403 P CONC...