Diamatic BMG-555 ULTRAPRO User manual

FOR MORE INFORMATION VISIT WWW.DIAMATICUSA.COM
Diamatic 05/2013 ● This document is not contractual ● Design and technical specifications may be subject to changes
SERVICE MANUAL
BMG-555 ULTRAPRO
VERSION 1.7
For serial numbers21853Band above.

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Index
1. Tools& Accessories 03
2. Spare parts 04
3. Tool plates 16
4. Fault diagnose frequency drive 18
Maintenance log 23

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1. Tools & Accessories
See the service manual for all spare parts and visit our website for the complete list of all accessories,
grinding tools, polishing pads and bush hammers.
E07185-1
DIAMAG
ADAPTER PLATE
Ø185 MM
BG707321
#18 - 20
BG707322 #30 - 40
BLUE GRINDING WING
BG707311
#18 - 20
BG707312 #30 - 40
BG707313 #60 - 80
BG707314 #120 - 150
GREEN GRINDING WING
BG707301
#18 - 20
BG707302 #30 - 40
BG707303 #60 - 80
BG707304 #120 - 150
RED GRINDING WING
BG707341-2
#30 - 40
BLACK GRINDING WING
E10691
DIAMAG
ADAPTER PLATE
WINGS PCD
Ø185 MM
BG200997-1/SET
PCD GRINDING WING
BG200999-1/SET
PCD GRINDING WING 2 X 1/4
BG200995-1/SET
PCD GRINDING WING 1 X 1
E07459
ROTARY PLATE ONLY Ø185 MM
E07460 PLATE Ø185 MM
COMPLETE WITH BUSH
HAMMER ROLLERS
BG300118-1 PLATE Ø185 MM
COMPLETE WITH STAR
WHEELS
E09119-2H
BUSH HAMMER
ROLLER
Ø50 MM
BG300109
CUTTER WHEEL
Ø50 MM
BG185001
#40 #1 - orange
BG185002 #100 #2 - Black
BG185003 #200 #3 - Blue
BG185004 #400 #4 - Red
BG185005 #800 #5 - White
BG185006 #1500 #6 - Yellow
BG185007 #3000 #7 – Green
POLISHING PADS Ø185 MM
BG185M004
#400 #4
BG185M005 #800 #5
BG185M006 #1500 #6
BG185M007 #3000 #7
MAINTENANCE PADS Ø185 MM
005014SR
10 M SUCTION HOSE
Ø76 MM
E09399/FINE
VELCRO PLATE
Ø185 MM
For Polishing pads
E09399/COARSE
VELCRO PLATE
Ø185 MM
For Maintenance pads

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2. Spare parts
Fig. 01 Frame complete

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Frame complete
Item
Part number
Description
Remarks
Qty.
1
BG005841_7
Tube cap round
2
2
E11229_RD
Steer handle
1
3
BE0721
Knob M10
2
4
BE0191
M6x50 hexagon socket head bolt
DIN 912
4
5
BG11760
Deadman switch
1
6
BG11758
Cord for deadman switch
1
7
BG11759
Key for deadman switch
1
8
E11227
Unlocking handle
1
9
BE0702
M8x40 eye bolt
2
10
E11284
M12x22 Resilient pressure piece
1
11
E11226
Deadman switch cover
1
12
BE0653
Hook
2
13
E07008
Chain (11links)
1
14
E11222
Hose arm
1
15
E11228
Handle mounting shaft
1
16
E10853
Electrobox 5,5kW 1x230V
1
E12458
Electroset 1x230V 5.5kW
Keypad
1
17
BG11920/32
Electrical inlet 32A
1
18
E11217
Electrobox bumper strip
1
19
E11236
Wheel shaft - BMG
2
20
BE0097
Starlock ring diam.20 with cap
2
21
E01491
Wheel
2
22
E11231
Diamatic logo red
2
23
E11059_RD
555 logo red
2
24
BE0040
M10x30 bolt
2
25
E11215
Right side of frame
1
26
E11230
Bottom electrobox bracket
1
27
E11218
Stiffening shaft
3
28
E01492
Megi bush
2
29
E11119
Spring lock 5mm
2
30
E11121
Hinge bolt
2
31
E11216
Left side of frame
1
32
E11235
Front cover Diamatic
1
33
E11219
Handle mounting bracket
1
34
BE0702
M8x40 eye bolt
2
35
E11220
Locking shaft
1
36
E09237
Spring 14, 8x64x2,0
2
37
E10380
Push strip
1
38
E11221
Main handle
1
39
E11224
Control box cover
1
40
E11124
Hinge 40x40
1
41
E06861
Operating box complete
Star/delta
1
E07882
Operating box complete
Speed control
1
E01543
Emergency stop
E00360
Signal light red complete
E01318
Start button
E01323
Left/right switch
E05130
Make contact (green)
E05131
Potentio meter complete (speed switch)
42
999-9156
Pipe clamp set
2

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Fig. 01.2 Handle complete for Keypad

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Fig. 01.2 Handle complete for Keypad
Item Part number Description Remarks Qty.
65
E12380
Keypad cover
1
66
E06446
Magnet
2
67
E12375
Handle
1
68
E12404
Hinge
1
-
BE0952
M5x16 Countersunk head screw
Not shown
2
-
BE0901
M5 Hex Flangelocknut/ins
Not shown
4
69
E13002
Emergency stop
1
70
999-9156
Pipe clamb (set) 35mm
2
71
BE0191
M6x50 Hexagon socket head
4
72
BE0184
M5x30 Hexagon socket head
2
73
BG11760
Deadman switch
1
74
BE0180
M5x12 Hexagon Socket Head cap
DIN912
1
75
BE0310
M5 Spring lock washer
5
76
BE0304
M5 Washer
5
77
E11226
Deadman switch cover
1
-
BE0901
M5 Hex Flangelocknut/ins
Not shown
2
78
BE0712
Wire rope clamp 8mm DIN741_555
1
79
E11227
Unlocking handle
1
80
E10388
Tension spring
1
81
BE0054
M10x30 Hexagon Socket Head Cap
1
82
BE0004
M10 Washer
2
83
E10380
Push strip
1
84
E12379
Cover plate
1
-
BE1066
M6 Self-locking hex flange nut
Not shown
4
85
E12369
Keypad
1
86
BE0180
M5x12 Hexagon Socket Head cap
DIN912
4
-
BE0304
M5 Washer
4
87
BE0653
Snap hook
2
88
E07008
Chain for dusthose
11 links / 36 cm
1
89
BE0232
M10x50 hexagon bolt
1
90
E11284
M12x22 Resilient pressure piece
1
-
BE0075
M12 Hexagon nut (low)
Not shown
1
91
E11222
Hose arm
1
92
E11557
Cover steer handle
1
93
BE0702
M8x40 eye bolt
1
94
E11220
Locking axle
1
95
E09237
Spring 14,8x64x2,0
2
96
E10556
Spring axle
2
97
E11228
Handle mounting shaft
1
-
BE0580
M10x20 hex. socket head cap s. DIN912
Not shown
2
-
BE0006
M10 spring lock washer DIN127B
Not shown
2
-
BE0062
Washer M10x30x1,5
Not shown
2

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Fig. 02 Machine complete

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Machine complete
Item
Part number
Description
Remarks
Qty.
42
BG-BRUSH20mm
Synth. Brush for 550
2m
43
BE0020
M6x20 Hexagon socket head cap
4
44
E11028
Rubber seal of floating shroud
1
45
E11027
Tightening steel strip
1
46
E11014
Floating shroud BMG-55
1
47
BE0642
M6 8x8 hex. Socket head shoulder
1
48
E11008
Protection cover BMG-555
1
49
E11187
Rubber bumper 30-20
1
50
E11120
Holder
2
51
BE0107
Retaining ring for bore Ø 80mm
1
52
BE0126
Retaining ring for shaft Ø 50mm
DIN 471
2
53
E07277/Dual/RD
Motor 5,5kW 3x230/400/1500rpm B5
1500RPM
1
54
E10231
Fill-up block steel
1x on 230V version
2
E10231-ALU
Fill-up block aluminium for 1x230V
Only on 230V version
1
56
E11012_2
Spider for totex 28
1
57
E11012_1
Bottom coupling
1
58
E11058
Bearing
1
59
E11010
Main pulley-BMG-555
1
60
E03993
Retaining ring for bore Ø 90mm
1
61
E11057
Bearing
1
62
E06048
Central bearing housing top
1
63
E11030
Top drive belt
1

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Fig. 03 Upper & Lower Drive system

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Drive system
Item
Part number
Description
Remarks
Qty.
64
E11181
Balancing plate
2
65
E11182
Balancing plate-2
1
66
E11029
Plug for bearing housing
3
67
E11013
V-seal Low drive BMG-555
1
68
E09985
Housing BMG-555
1
69
E11061
Tension pulley assembly BMG-555
1
70
E11047
Cover plate tension pulley BMG-555
1
71
E11044
Cover plate contra pulley BMG-555
1
72
E11060
Contra pulley axle assembly BMG-555
1
73
E11183
Balancing plate-3
1
74
E11022
Pulley complete BMG-555
3
75
E11175
Tension pulley mount ring
1
76
E11006
Drive pulley compl.BMG-555
1
77
E01503
Centre ring
1
78
BG11905
HDT belt - drive
1
79
E11034
Lower plate BMG-555
1
80
BG007850
Inspection cover
2
81
BG11797
V-seal
3
82
BG005827
Cover
1
83
BG005826
Ring
3

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Fig. 04 Tension pulley assembly - E11061
Item
Part number
Description
Remarks
Qty.
84
E06051
Pulley
1
85
BE0129
Retaining ring for shaft Ø 12
DIN 471
1
86
BE0128
Retaining ring for bore Ø 28
DIN 472
2
87
E06203
Bearing
2
88
E11046
Tension pulley axle (PK belt BMG-555)
1

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Fig. 05 Tension pulley assembly – E11060
Item
Part number
Description
Remarks
Qty.
89
Retaining ring for shaft Ø 13
DIN 471
1
90
E06050
Pulley
1
91
Key 5x5x20
DIN 6885A
1
92
BE0076
Retaining ring for shaft Ø 25
DIN 471
3
93
BE0077
Retaining ring for bore Ø 52
DIN 472
2
94
222-2321-E
Bearing
2
95
E09986
Contra pulley axle – BMG-555
1
96
BE0109
Key 8x7x20
DIN 6885A
1
97
E11005
Bearing housing contra pulley – BMG-555
1
98
RB165-2
Pulley
1
99
E11062
Taper lock

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Fig. 06 Drive pulley E11006
Item
Part number
Description
Remarks
Qty.
100
BE0256
Key 8x7x30
DIN 6885A
1
101
E11011
Central axle BMG-555
102
Key 10x8x35
DIN 6885A
1
103
E00718
Taper lock
1
104
E10312
Pulley
1
105
E00951
Retaining ring for bore Ø 62
DIN 472
2
106
E11040
Bearing house
1
107
B20404
Bearing
1
108
B21631
Retaining ring for shaft Ø 30
DIN 471
1

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Fig. 07 Pulley (3x) E11022
Item
Part number
Description
Remarks
Qty.
109
B21631
Retaining ring for shaft Ø30
DIN 471
3
110
E00951
Retaining ring for bore Ø62
DIN 472
3
111
BG11817
Bearing
2
112
E11023
Bearing housing
113
RB100A3-350
Taper lock
1
114
RB165-2
Pulley
1
115
BG005817
Bering housing
1
116
E09992
Axle pulley compl. BMG-555
1
117
BE0256
Key 8x7x30
DIN 6885A
1

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3. Tool plates
E10172-185 Buffer plate 185mm complete (3x per machine)
E12112 Bush hammer set up - 185mm (3x per machine)

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Tool plates
Buffer plates (E10172-185) will only be supplied as complete set
Item
Part number
Description
Remarks
Qty.
150
E10172-185
185mm buffer system
3
151
BE0011
M8x20 hexagon socket head cap screw
3
152
BE0456
M8x16 hexagon countersunk screw
3
153
E12065
Shock absorber
4 / 8
154
BE0187
M6x12 hexagon countersunk screw
8 /16
160-169
E12112
185mm Bush hammer set up 555
1
160
BG11805
Buffer plate
1
161
BG11806
Buffer soft blue
3
162
BE0584
M8 spring lock washer small
3
163
BE0725
M8x20 hexagon socket thin head cap
3
164
E07459
Cutterplate 185mm only
1
165
BE0023
M10 locking nut
3
166
E09119-2H
Bush hammer heavy incl. bolt & nut
3
167
BE0723
M10 12x55 hexagon socket head cap screw
3
165-167
E09119-2H
Bush hammer heavy incl. bolt & nut
3
E09119-2H/SET9
Bush hammer set of 9
E09119-2H/SET15
Bush hammer set of 15
168
BE0314
M8x30 plain washer
2
169
BE0030
M8x25 hexagon head screw
1
164-167
E07460
Cutter plate c.w. bush hammer 185
1
BG300118-1
Cutter plate c.w. star wheels
1
E07185-1
DIAMAG 185mm adapter plate
1
E09399/fine
Velcro plate 185mm fine
1
E09399/coarse
Velcro plate 185mm coarse
1
E10691
185mm Diamag PCD plate
1
BG200994
Plate for wings 185mm
1
BG200989
Dry polish dot holder 185mm
1
E06447
DIAMAG adapter plate for dots
3
BG185001 –
BG185007
Polishing pads 185mm
1
BG185M004 –
BG185M007
Maintenance pads 185mm
1

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4. Fault diagnose frequency drive
For a complete overview of faults and how to resolve them, scan the QR code which is on the front
of the frequency drive.
Does the inverter shows an “INF” fault, reset the machine.
If the machine does not work after that, call you distributor.
To reset the machine, put out the power supply and wait 5 minutes.
Then start up the machine again. Call a technician if the machine still not works.

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