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