Blastrac 2-45D User manual

Operating Instructions
2-45D
MAN-2-45D-EN (Freightliner)

Technical Data
Safety Instructions
General
Transport
Initial Operation
Operation
Maintenance
Electrical & Hydraulic Systems
Fault Diagnosis
Spare parts
Design and specicati ons are subject to
change w ithout notice - November 2008

2-45D Operating Instructions
Technical data
1
Contents Chapter 1
1.1 Rating
1.2 Unit specifications
1.3 Operative range and correct usage
1.4 Machine type designation
1.5 Advice for operators of blast cleaning machines

Operating Instructions 2-
45D
Technical data
2
1.1 Rating
Unit / designation : Blastrac blast cleaning machine
Machine type : 2-45D
Manufacturer : Blastrac BV
Utrechthaven 12
NL-3433PN Nieuwegein
THE NETHERLANDS
1.2 Unit specifications
Dimensions:
Machine 2-45D
Length 1576 mm
Width 1420 mm
Height 1415 mm
Weight 1650 kg
Power consumption (hydraulic system):
The indicated values correspond to normal operating conditions.
Power consumption Flow and pressure
Blast wheel drive
2 x 25 kW
2 x 64 l/min at 235 bar
Magnet drum motor 0,8 kW 4,8 l/min at 100 bar
Blower motor 22 kW 63 l/min at 210 bar
Required hydraulic flow: min. 200 l/min at 250 bar
Required cooling capacity: min. 22,5 kW
Required oil tank: min. 350 liters
Required drain lines for blast wheel motors: min. 1/2"
.....
Please contact Blastrac to get more details about other (hydraulic)
requirements for the 2-45D machine.

2-45D Operating Instructions
Technical data
3
Rated speed
Blast wheel speed 4000 min-1
Magnet drum speed 160 min-1
Blast wheel size : 2 x 349 mm Ø
Working width : 1150 mm
Required drive speed : 0 - 5,0 km/h
Blast cleaning output : up to 2000 m²/h
Dust hose connection : 2 x 150 mm Ø
Recommended abrasive : Shot 460-550
Abrasive consumption : 0,1 - 0,5 kg/m²
Recommended filter unit : 2-45 TDC
1.3 Operative range and correct usage
The 2-45D is exclusively designed to clean dry, frost-
free horizontal surfaces. The machine may not be
used for other purposes. The manufacturer will not
be liable for damage resulting from such incorrect
usage. In these cases the user assumes all risks.

Operating Instructions 2-
45D
Technical data
4
1.4 Machine type designation
1.5 Advise for operators of blast cleaning machines
In accordance with the accident prevention
regulations for blast cleaning work (VBG 48) the
operator must provide operating instructions for
blast cleaning work in a form and language that is
understandable.
The blast cleaning machine Operating Instructions
are only part of these operating instructions. Please
consult the current accident prevention regulations
for the precise content.
numberofblastwheels
blastcleaningwidth
productcode
2 - 45 D

2-45D Operating Instructions
Safety instructions
1
Contents Chapter 2
2.0 Warnings and symbols
2.1 Organisational measures
2.2 Personnel selection and qualification
2.3 Safety precautions applicable to different operating conditions
2.4
Special work within the scope of use of the equipment and
maintenance activities as well as repairs during operation
2.5 Definition of the Safety off position
2.6 Particular dangerous aspects of the equipment
2.7 Hydraulic and electrical engineering regulations

Operating Instructions 2-
45D
Safety instructions
2
2.0 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 all safety precautions that are to be
taken in order to ensure prevention to life and injury.
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 with regard
to possible risks to persons or to extensive material
damages.

2-45D Operating Instructions
Safety instructions
3
Warning against dangerous voltages.
Indications relating to protective devices in electrical
appliances.
Indications where consultation with the
manufacturer is required.
Instructions relating to periodical checks.
Reference to important instructions contained in the
Operating Instructions.
2.1 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 accident prevention and environmental protection must be
complied with and indicated!
Such duties may for example relate to the handling of hazardous
substances or to the provision and wearing of personal protection
equipment as well as compliance with traffic regulations.

Operating Instructions 2-
45D
Safety instructions
4
The Operating Instructions must be supplemented by instructions
including the duty to supervise and report relating to particular
working practices, for example work organisation, work procedures
and personnel allocation.
Personnel entrusted with working with the machine must have read
the Operating Instructions before starting work, in particular the
Safety Instructions chapter. To read these instructions during work
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 staff are to be checked
regarding awareness of safety and hazards.
Personnel must tie back long hair and not wear loose clothing or
jewellery including rings. There is a risk of injury through getting stuck
or being drawn into moving machinery.
Use personnel protection equipment if necessary or required by
regulations! Take notice of all safety and hazard notices on the
machine!
All safety and hazard notices at 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 immediately!
Changes, add-ons or conversions to the machine which might impair
safety must not be undertaken without the manufacturer’s
permission!
This applies in particular to the fitting and adjustment of safety
devices as well as to welding on load-bearing parts.
Spare parts must comply with the technical requirements specified
by the manufacturer. This is always guaranteed if original spare
parts are used.
Intervals for recurring checks and inspections specified in these
Operating Instructions must be complied with!

2-45D Operating Instructions
Safety instructions
5
To perform maintenance work correctly it is imperative to be equipped
with the proper tools for the task in question.
The location and the operation of fire extinguishers must be made
known on each building site!
Take note of the facilities for reporting and fighting fires!
2.2 Personnel selection and qualification
Fundamental duties :
Work on the machine may only be undertaken by reliable personnel.
Only trained personnel may be deployed. Note the statutory
minimum age! Specify clearly the responsibilities of personnel for
operation, setting up, servicing and maintenance work!
Make sure that only authorised personnel operate or work on the
machine!
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 deployed on the machine under constant supervision of an
experienced person!

Operating Instructions 2-
45D
Safety instructions
6
2.3
Safety precautions applicable to different operating
conditions
Ban any method of working that impairs safety!
Only operate the machine when all safety devices and related
safety equipment, e.g. detachable safety devices, emergency
stops and suction devices are present and operational!
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, and the fault must be rectified!
Secure the work area around the machine in public areas
providing a safety distance of at least 2m from the machine.
Before switching on the machine make sure that no-one can be
endangered when the machine starts up!
Do not switch off or remove the exhaust and ventilation devices when
the machine is running!
All persons in the proximity of the machine must wear ear
protectors, safety glasses with lateral protection as well as safety
shoes. The operator is obliged to wear close-fitting protective
clothing.

2-45D Operating Instructions
Safety instructions
7
2.4
Special work within the scope of use of the equipment and
maintenance activities as well as repairs during operation
Mechanical servicing work:
Put the machine in the Safety off position as described in chapter
2.5 for any servicing work on the machine in order to prevent the
machine from being switched on accidentally.
Please follow any special safety instructions in the various chapters
on servicing the machine.
See chapter 7.1 - 7.9.
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.
Do not use any aggressive cleaning materials!
Use lint-free cleaning cloths!
Always tighten any screw connections that are undone during
servicing and maintenance work!
If safety devices need to be dismantled during setting up, servicing
and repairs, 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!
Hydraulic servicing work:
Make sure that hydraulic components used for replacement purposes
comply with the original parts and are correctly adjusted if necessary.
For safety notes see 2.7 Hydraulic and electrical engineering
regulations.

Operating Instructions 2-
45D
Safety instructions
8
2.5 Definition of the Safety off position
Definition:
The machine is in a safe condition when it cannot generate any
hazard.
Putting the equipment in the Safety off position means:
Close the shot valves.
Switch off the blast machine.
Switch off the dust collector.
Wait for standstill of all drives.
Disengage the hydraulics - Switch off PTO.

2-45D Operating Instructions
Safety instructions
9
2.6 Particular 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
safety regulations during operation and maintenance of safety
devices supplied with the machine as well as the provision of
appropriate additional safety devices!
1. Blast housing outlet
Danger of injury!
Abrasive leaves housing with
high speed!
Moving parts!
Lift and cant the machine only
when it is in Safety off position.
It is not allowed to stay within
the working radius of the
machine!
2. Wheels
Danger of injury!
Moving parts!
It is not allowed to stay within
the working radius of the
machine!

Operating Instructions 2-
45D
Safety instructions
10
2.7 Hydraulic and electrical engineering regulations
Work on hydraulic
equipment or operating materials may only be
undertaken by a skilled hydraulic engineer or by trained
persons
under the guidance and supervision of a
skilled hydraulic
engineer as well as in accordance with the
hydraulic engineering
regulations.
Work on electrical
equipment or operating materials may only be
undertaken 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.
Hoses and pipe work can be under hydraulic pressure
.
Temperature of the components can be above 37° C
. Use only
hoses and pipe work that are sized and marked in accordance with
the overall power consumption of the machine.
The hydraulic and electrical equipment for the plant must be
inspected regularly. Please note in particular the specified
recurring inspections. Defects such as loose connections or
scorched hoses and cables must be rectified immediately. Call a
skilled hydraulic or electrical engineer or our Customer
Services.
A second person must be deployed who can disengage the
hydraulics and switch off the PTO in an emergency if work on live
parts is necessary. The work area must be sealed off using a red and
white safety chain and a danger sign. For the electrical parts, use a
tool that is insulated against voltages.
Only start work once you are familiar with the hydraulic and
electrical engineering regulations that apply to your area.
Only use voltage seekers that comply with the regulations when
troubleshooting. From time to time check voltage seekers to ensure
that they are operationally efficient.

2-45D Operating Instructions
General
1
Contents Chapter 3
3.1 Introduction
3.2 Operating instructions
3.3 Hydraulic connections
3.4 Care and maintenance
3.5 Scope of supply
3.6 Description
3.7 Blast wheel
3.8 Separator, magnetic drum and hopper
3.9 Abrasive sealing
3.10 Air suction and filter system
3.11 Abrasive media

Operating Instructions 2-
45D
General
2
3.1 Introduction
Blastrac wants to thank you for your decision to employ the blast
cleaning machine 2-45D for the treatment of horizontal surfaces.
The machine has a closed abrasive circuit with dust separation. This
comprehensively avoids damaging the environment and endangering
the operating staff.
The 2-45D is designed to remove coatings, non-skid, epoxy, bitumen
and asphalt on different types of horizontal surfaces.
3.2 Operating instructions
This manual has been written to support the operating personnel on
learning the functioning of the machine and to guarantee optimum
operation and maintenance.
Therefore it is important that all persons operating and
maintaining the machine read this manual carefully and
understand it fully.
The supplied machine has been manufactured for being employed in
the user’s country. All descriptions and notes have been formulated in
the language of the user’s country or in English in accordance with
the statutory regulations, or shown as pictograms. If the customer
deploys personnel with little knowledge of the language of the user’s
country, appropriate instruction and training must be provided.
Before using the machine personnel must be familiar with how
to operate the machine, with all important components, with the
method of working and with its dimensions.
Blastrac offers a course on the use of the machine in order to make
the operating and maintenance personnel familiar with all elements of
the blast cleaning machine.

2-45D Operating Instructions
General
3
Initial commissioning of the machine must be carried out very
carefully. The machine operator must fully understand the sequence
of commissioning of the individual parts and their functioning.
All persons in the proximity of the machine in op
eration must wear
ear protectors, safety glasses with lateral protection and safety
shoes. The machine operator must wear close-
fitting protective
clothing.
3.3 Hydraulic connections
Flow Pressure
Blast wheel drive 2 x 64 l/min 210 bar
Magnet drum motor 8 l/min 100 bar
Blower motor 63 l/min 180 bar
Required hydraulic flow: min. 200 l/min at 230 bar
Required cooling capacity: min. 50 kW
Required oil tank: min. 350 liters
Required drain lines for blast wheel motors: min. 1/2"
.....
Please contact Blastrac to get more details about other (hydraulic)
requirements for the 2-45D machine.
3.4 Care and maintenance
Special attendance and regular maintenance of the machine and its
parts are imperative for functioning and safety.
In order to prevent unnecessary downtimes it is recommended to
keep original spare and wear parts on stock as listed in the
maintenance box.
A list of contents of the maintenance box is provided in Chapter 10 to
enable the above-mentioned work to be carried out quickly.