Blastrac 1-16DB4-V2 User manual

SERVICE MANUAL 1-16 DB4-V2
VERSION 1.1
www.blastrac.com 1-800-256-3440

Contents
1. Introduction..............................................................................................................................3
2. Safety ......................................................................................................................................3
Advice for Operators of Blast Cleaning Machines ..................................................................3
Warnings and Symbols .....................................................................................................3
Organizational Measures ...................................................................................................4
Fundamental Duties .........................................................................................................5
General Safety Precautions ...............................................................................................6
Definition of the Safety Off Position ....................................................................................8
3. General ....................................................................................................................................9
Operative Range..............................................................................................................9
Scope of Supply...............................................................................................................9
Description of the Machine ................................................................................................9
Care and Maintenance ......................................................................................................9
4. Transportation ........................................................................................................................ 10
Unit Specifications ......................................................................................................... 10
General Transport of the Machine .................................................................................... 10
Tie-Down Locations ........................................................................................................ 11
5. Operation ............................................................................................................................... 12
Preparation for Operation................................................................................................ 12
Operator Awareness....................................................................................................... 13
Engine Startup .............................................................................................................. 14
Operation Adjustments ................................................................................................... 17
Operation Sequence ....................................................................................................... 18
Dust Collector Function...................................................................................................20
Dust Collector Parts ....................................................................................................... 21
Shutdown Sequence....................................................................................................... 22
Safety Shutdown ........................................................................................................... 22
6. Maintenance ........................................................................................................................... 23
Blade Replacement ........................................................................................................ 23
Pinch Bar Removal, Installation, and Re-Positioning ........................................................... 25
Blast Wheel Removal and Installation ............................................................................... 27
Liner Removal and Stack up ............................................................................................ 29
Dust Collector Maintenance ............................................................................................. 32
Filter Cartridge Removal .................................................................................................32
Engine Maintenance ....................................................................................................... 33
Clutch Maintenance ........................................................................................................ 40
Grease Points ................................................................................................................42
Electrical....................................................................................................................... 44
Spare Parts ................................................................................................................... 47
7. Contact .................................................................................................................................. 50
2

1. Introduction
It is important that all persons who are working with. or maintaining this machine,
read the manual carefully and understand it fully. Keep this manual near the machine,
to enable it to be referred to at any time. Only authorized personnel may operate this
machine.
2. Safety
Before operating the machine, the personnel must be familiar with the safety
instructions given in this manual. Keep this manual near to the machine, so it can
always be consulted.
Advice for Operators of Blast Cleaning Machines
Warnings and Symbols
3
In accordance with the accident prevention regulations for blast cleaning
work, the operator must provide operating instructions for blast cleaning
work in a form and language that is understandable.
During operation the acceptable noise level of the 1-16DB4-V2 could
exceed 85dB (A). This noise level depends on the job site. When the noise
level is 85 dB (A) or more, the machine operator and persons working near
the machine must wear sound-insulating equipment. However, it is the
contractor’s responsibility to ensure the safety of their operator.
Engine exhaust gases contain poisonous carbon monoxide. Carbon
monoxide is odorless and colorless and can cause injury or death if inhaled.
Do not use equipment indoors without adequate ventilation. Refer to OSHA
guidelines and regulations concerning maximum levels of exposure to
carbon monoxide gases and other hazards associated with using internal
combustion engines.
Symbol of operational safety:
In these operating instructions, this symbol will be shown next 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.
Information, instructions, and restrictions with regard to possible risks to
persons, property, or equipment.

Organizational Measures
In addition to these operating instructions, general and legal regulations regarding
accident prevention and environmental protection must be compiled with per local
regulations.
Such duties may, for example, relate to the handling of hazardous substances, or the
provision and wearing of personal protection equipment, as well as compliance with
traffic regulations.
The operating instructions must be supplemented by other instructions, including the
duty to supervise and report incident relating to particular working practices, for
example work organization, work procedures, and personnel safety.
Personnel entrusted with working 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 setting up the equipment, carrying
out maintenance work or training staff to work with the machine.
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. There is a risk of injury by items getting caught, or being drawn into moving
machinery.
4
Indicates where consultation with the manufacturer is required.
Instructions relating to periodic checks.
Reference to important instructions contained in the operating
instructions.
These operating instructions are to be kept with the machine, and must
be within reach at all times!
Use personal protective equipment if necessary or required by local
regulations! Take notice of all safety and hazard notices on the machine!

All safety and hazard notices or on the machine must be kept complete and legible.
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 and
remedied.
Spare parts must comply with the technical requirements specified by the
manufacturer. This is always guaranteed if Blastrac OEM parts are used.
Intervals for recurring checks and inspections specifies in these operating
instructions must be followed.
To perform maintenance work correctly, it is imperative to be equipped with the
proper tools for the task.
The location and the operating of fire extinguishers must be made known to each
work site.
Take note of the facilities for reporting and fighting fires.
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 traffic safety
regulations, and inform him not to take instructions from third parties who may not
be complying with the local safety requirements.
Personnel, who are being trained to operate equipment, may only use the machine
under constant supervision of an experienced person.
5
Changes, additions, and conversions to the machine must NOT be made
without the manufacturer’s permission! This applies in the particular to
the fitting and adjustment of safety devices.

General Safety Precautions
Do not allow any method of working that impairs safety.
Recognized official procedures have to be used to ensure the machine is operated in
the safest and best conditions.
Check the machine visually for any damage and defects at least once a day.
In the event of operational malfunctions, the machine must be shut down immediately
and secured. This is accomplished by pushing the top of the throttle assembly down
and turning the ignition switch to the off position.
Faults must be immediately remedied.
Carry out 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.
Do not wear loose fitting clothing.
Do not stand to the side of the blast housing.
Do not operate this equipment on wet surfaces or in the vicinity of flammable liquids.
6
Only operate the machine when all safety devices, and related safety
equipment, are present and operational.
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.
All persons in the proximity of the machine must wear ear protection, safety
glasses with side shields and safety shoes. In addition, the machine
operator must wear close fitting protective clothing.
Engine exhaust gases contain poisonous carbon monoxide. Carbon
monoxide is odorless and colorless and can cause injury or death if inhaled.
Do not use equipment indoors without adequate ventilation. Refer to OSHA
guidelines and regulations concerning maximum levels of exposure to
carbon monoxide gases and other hazards associated with using internal
combustion engines. It is highly recommended that a CO (carbon
monoxide) detector be used to warn the user if levels become unsafe.

Mechanical servicing work:
Put the machine in the Safety Off Position as described on page 8 before carrying out
any service work on the machine.
Follow any special safety instructions in sections on servicing the machine. See
Section 5.
Service and maintenance intervals specified in these Operating Instructions, as well
as information on the replacement of parts must be followed.
These activities may only be undertaken by qualified personnel.
The operator must be given information about maintenance and work procedures
before starting the cleaning process. This includes, but is not limited to the following:
•Procedures that are related to normal operation
•Methods of tool adjustments on the machine, and its safety devices
•All “ON and OFF” functions that have 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.
See page 8 for specific details of the Safety Off Position.
Always dispose of the contents of the dust bags or of a connected dust collector
before loading the machine onto a vehicle.
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.
Always verify that all belts are in good condition.
If safety devices need to be removed or dismantled during service and repair, these
safety devices must be reinstalled, and inspected immediately after completion of the
servicing and repair work.
Make sure that process materials and replaced parts are disposed of safely and in an
environmentally friendly manner.
Make sure that all components used for replacement purposes comply with the
original parts and are correctly adjusted if necessary.
7

Definition of the Safety Off Position
Definition: The machine is in a safe condition where it cannot be a hazard.
Putting the equipment in the Safety Off Position involves:
Close the shot valve.
Switch off the machine.
Wait for all drives to stop.
Securing against unintended restart.
8

Operative Range
3. General
The Blastrac 1-16DB4-V2 is a downward blasting machine with a closed abrasive circuit
designed for the pre-treatment of horizontal surfaces. The impact of metallic abrasive
onto the surface to be treated thoroughly removes surface contaminants, coats of
paint, sealants and thin coatings.
This machine has an on board dust collector that separates the dust from the abrasive.
The specially designed dust collection system ensures dust-free operation of the
machine and clean air at the workspace.
Scope of Supply
Scope of supply of the machine:
Blast cleaning machine (1-16DB4-V2)
Operating instructions
Description of the Machine
The 1-16DB4-V2 Shot-Blast machine is powered by a 61 HP Duetz Diesel engine. The
machine is capable of removing up to 1/4 inch of concrete in one pass. It is driven by
a hydrostatic pump and motor system.
The 1-16DB4-V2 has a 16-inch blast pattern using a patented blast wheel design which
eliminates hot spots and grooves. The blast wheel is a paddle wheel design that is
pulley driven by a mechanical clutch. Shot feeds through the shot valve to the blast
wheel. The shot and debris rebound to the dust separator and the dust is removed to
the dust collector. Clean shot falls back into the hopper for reuse. The machine recycles
shot continuously after the clutch is engaged until the machine is shut off. The auto
pulse dust collector cleans the nine cartridge filters while the machine is running. This
machine is capable of blasting up to 4000 square feet per hour while achieving a brush
blast.
Care and Maintenance
Special care and regular maintenance of the machine are imperative for proper
function and safety.
In order to prevent unnecessary downtime, it is recommended to keep original spare
and wear parts in stock, as listed in the later parts of this manual.
Before each use of the machine, verify the readiness of the machine by reviewing
the checklist on pages 11-12.
9
All persons in the proximity of the machine must wear safety glasses with
lateral protection and safety shoes while the machine is in operation. The
machine operator must wear close-fitting protective clothing.

Unit Specifications
4. Transportation
1-16DB4-V2
Length
116 in
Width
60 in
Height
66 in
Weight
4500 lbs.
Blasting Width
16 in
General Transport of the Machine
Before the machine is used for the first time, Blastrac authorized dealers offer a course
to familiarize maintenance and operating personnel with all elements of the machine.
Blastrac is not liable for damage caused by incorrect use of the equipment by personnel
that have not trained by Blastrac.
Before the machine is transported, remove the abrasive from the machine and clean
the dust out of the dust collector.
Always drive carefully and in a manner to avoid the machine shifting. Tighten the
machine to the vehicle or trailer with straps or chains.
This machine is equipped with a tow valve. This valve allows fluid to pass through
the hydraulic pump without the motor being started. This allows you to move the
equipment without the use of the motor. If the valve is not closed, it will allow fluid
to pass through the pump and not move when the engine is stared. The valve is
located on the side of the hydraulic pump (see picture). Turn clockwise to close
(normal operation), turn 180° counter-clockwise to open (tow operation).
10
Tow Valve

Tie-Down Locations
There are 4 tie-down locations, as show below.
Front Tie-Downs
Side Tie-Downs
11

Preparation for Operation
5. Operation
Check the surface to be treated for loose parts (stones, screws, etc.). The surface
must be swept, if necessary. Make sure that the machine can travel over all
inequalities on the surface. Small inequalities like weld seams or floor joints are no
barriers for the machine.
Before start up, make sure that all existing protective housings are mounted and
properly tightened.
Carry out the following checks before any start-up. A printable checklist is provided in
the back of this manual for your convenience.
Check whether all machine parts are assembled safely and correctly.
Verify that all bolted connections are secure and tight.
Check the abrasive storage hopper and the blast wheel parts for foreign
materials and remove them.
Check the blast wheel blades, liners and fastening screws for damage and
wear. Important Note: The blades should be changed before they wear past the vanes
on the blast drum.
Check the brush seals for wear.
Check the pinch bar for clearance and uneven wear.
Verify for proper gap between the pinch bar and the blades. See page 25 on
adjustment instructions.
Check the Blast Wheel bearings set screws and grease.
Check the shot valve for leaks.
Make sure the filters are not clogged or torn.
Check the wheels/tires for damage.
Check the engine oil and change when dirty.
12
Whenever the machine is not used for blast cleaning, the abrasive valve
must always be closed!
All persons in the proximity of the machine must wear safety glasses with
side shields, as well as safety shoes. The operator must wear close-fitting
protective clothing!
Regular inspection is important in order to avoid unplanned downtime.

Check the air cleaner and change when dirty.
Check the hydraulic fluid and change when dirty.
Check the Blast Seals for excessive wear.
Check the Blower Bearings set screws and grease.
Check the chain tension in the steering assembly.
Check the condition and tension of the belts.
Check the bearing in the idler assembly.
Make sure the dust bags are empty.
Important Note: Please comply with the local waste treatment regulations considering
the removed material.
Check the dust collector latches and ensure thay they firmly secure the door.
Check the separator parts for wear and defects. Remove foreign bodies and
dust deposits in order to prevent the separator from being blocked.
Check the level of abrasive in the storage hopper. Refill if necessary.
Any items on this list that are not found to be in order must be repaired or replaced.
Operator Awareness
The 1-16DB4-V2 machine is designed to blast a concrete surface and reclaim all
shot and dust. The machine can very easily destroy the concrete surface if not
operated properly! The absence of operator awareness will create down time and
can prove to be very costly.
•When the shot valve is open, the machine is throwing shot! Therefore, you
must be sure the shot valve is closed prior to starting as well as any time
the machine comes to a stop.
•The speed of travel controls the level of removal. You should run a test
pattern to be sure you are not gouging the floor.
•Due to variances in concrete, it is necessary to check the pattern every
ten feet as the concrete or coated surface may be softer in different areas.
•The maintenance check list on page 12-13 is provided for blasting
efficiency. This list should be completed after each day of blasting.
•If the dust bags get too full, you will lose all of your suction. This will result
in loss of all shot from the hopper. 13
Engine exhaust gases contain poisonous carbon monoxide. Carbon
Monoxide is odorless and colorless and can cause injury or death if inhaled.
Do not use equipment indoors without adequate ventilation. Refer to OSHA
guidelines and regulations concerning maximum levels of exposure to
carbon monoxide gases and other hazards associated with using internal
combustion engines. It is highly recommended that a CO (carbon
monoxide) detector be used to warn the user if levels become unsafe.

Engine Startup
•The gap between the blades and the pinch bar is very important. If your
gap exceeds 3/16 inch, you will begin to trail shot and eventually empty
the shot hopper.
•The shot blast machine is equipped with blast seals. These seals provide
a seal for the suction required. They contain shot that would otherwise be
thrown from the machine. If the seals are worn out, you will lose your
seal and shot could escape from the worn areas.
Before start-up, the operating personnel must be familiar with the safety
regulations given in this manual.
14
Engine exhaust gases contain poisonous carbon monoxide. Carbon
monoxide is odorless and colorless and can cause injury or death if inhaled.
Do not use equipment indoors without adequate ventilation. Refer to OSHA
guidelines and regulations concerning maximum levels of exposure to
carbon monoxide gases and other hazards associated with using internal
combustion engines. It is highly recommended that a CO (carbon
monoxide) detector be used to warn the user if levels become unsafe.
All persons in the proximity of the machine must wear safety glasses with
lateral protection as well as safety shoes. The operator is obliged to wear
close-fitting protective clothing.

GAUGES:
VOLTS- shows the voltage being supplied from the
charging system.
FUEL LEVEL- show the amount of diesel in the fuel
tank.
ENGINE RPM- shows the current revolution per minute
of the engine.
OIL PRESSURE- shows engine oil pressure in pounds
per square inch.
ENGINE HOURS- shows engine operating hours.
ENGINE TEMP- shows the current engine temperature
of engine.
WARNING LIGHTS:
CHARGE FAILURE- lights when alternator is not
charging.
PREHEAT- lights when glow plugs are in use.
LOW OIL PRESS- lights when oil pressure becomes
too low to safely run.
HIGH TEMP- lights when temperature of engine
becomes excessive. Figure 1
15

Before starting the engine, make sure the clutch is in the disengaged
position. Failure to do so will result in damage to the clutch.
“Cold” Startup Procedure:
1) Turn the ignition switch to the run position and wait for the glow plug light to
turn off.
2) After glow plug light turns off, turn the key all the way to start.
Note: You must turn ignition past the ignition interlock for the starter to engage.
3) Release key after engine turns over.
4) Place throttle to full/open position and operate as normal.
“Hot” Startup Procedure:
1) Turn ignition to start position.
Note: Due to the engine being at operating temperatures you do not have to wait
for the Glow plugs to warm the engine block.
2) Release key after engine turns over.
3) Place throttle to full/open position and operate as normal.
“Dry” Startup Procedure:
This procedure shall be followed if the fuel system has been run dry (out of fuel).
1) The engine must be primed using the priming plunger.
Figure 2
2) After priming the engine, follow the “Cold” startup procedure.16
Fuel Pump
Primer

Operation Adjustments
The 1-16DB4-V2 is equipped with a few fine tune adjustments to make blasting
easier.
1. Front End Lift: This is used primarily for loading and unloading the machine. This
feature may also be used to adjust your seals while operating the machine,
opposed to stopping the machine and doing it manually.
2. Silencer Box: This is used to adjust the amount of vacuum pulled through the blast
housing. It can be used to fine tune air flow to the specific application.
3. Pinch Bar: The pinch bar clearance must be checked before each operation. For
best blasting results, adjust the pinch bar 1/8-inch clearance for all applications.
4. Dampener Plates: This feature allows you to adjust the blast pattern if needing a
thinner blast width such as in line stripe removal or other special applications.
17
After Adjusting the pinch bar to blade gap, always spin the blast wheel to
verify clearance on all blades.

Operation Sequence
Figure 3
Refer to Figure 3 for the location of switches and controls identified in this
procedure.
1. Complete the Operation/Maintenance Checklist (pages 12-13).
2. Place the transmission control lever in the neutral (center) position.
3. Follow the startup procedures in on page 16, as appropriate.
4. Pull the throttle to the wide open position.
5. Push the transmission lever forward for forward motion and backward for
reverse motion.
6. Start the machine moving forward and slowly open the shot valve. The slower
the machine travels while the shot valve is open, the deeper the profile.
7. When coming to the end of a pass, close the shot valve about five feet before
stopping. This will allow you to clear the housing of shot keeping you from
blasting a hole when you come to a complete stop.
18
Throttle
Transmission
Control
Shot Valve
Control
Open / Close
Blast Head
Raise / Lower
Always blast in a forward direction.
The dust container of the dust collector must be emptied regularly.
Comply with your local waste treatment regulations considering the
removed material.

8. Only operate this machine when sitting in the operator seat.
DO NOT OPERATE THIS MACHINE WHEN STANDING IN FRONT OF IT!
Figure 4
19

Dust Collector Function
This unit is equipped with an auto pulse dust collector that provides suction to separate
the dust from the shot. Refer to Figure 5 for the location or items discussed in this
section.
The central part of the dust collector is the filter chamber. Dust laden air enters the
chamber from the blast head through the exhaust hose and into the dust collector
inlet connection located on the center, front side of the dust collector. The dirty air
passes through a plenum and flows through an array of nine vertically mounted,
specially designed filter cartridges. Dust is captured on the surface of these filters
allowing clean air to pass to the clean air portion of the dust collector where it exhausts
to the open atmosphere through the silencer box.
The dust that was trapped on the external surface of the filters is periodically
removed by pulsing the filters with a burst of compressed air released from the
header tank by a diaphragm valve. The air is delivered via one of three blow-down
tubes. This momentary pulse of air allows the dust to fall into the dust bags at the
bottom of the filter chamber. Three filters are pulsed at a time, in sequence,
determined by a timer board located in the control box located on the front of the
dust collector, just above the inlet. This timer board is usually set to pulse a three
filter bank every ten seconds. The timer board determines the time between pulses
and the duration of each pulse. Venturi valves are located above each filter for
maximum filter cleaning efficiency.
20