Marco BLASTMASTER 156E User manual

Before using this equipment, read, understand and follow all instructions
in the Operator’s Manuals provided with this equipment. If the user and/
or assistants cannot read or understand the warnings and instructions,
the employer of the user and/or assistants must provide adequate and necessary training to
ensure proper operation and compliance with all safety procedures pertaining to this equipment. If
Operator’s Manuals have been lost, please visit www.marco.us, or contact Marco at 563.324.2519
for replacements. Failure to comply with the above warning could result in death or serious injury.
BLASTMASTER®156E
REMOTE CONTROL SWITCH
OPERATOR’SMANUAL

Blastmaster®156E Remote Control Switch
1
Company Profile
Since 1944, Marco has developed a strong tradition of providing innovative and reliable products and services to the
surface preparation and protective coatings industries. We are the world’s premier provider of Abrasives, Blasting,
Coating, Dust Collectors, Engineered Systems, Rental, Safety, Service, Repair, & Modernization, and Vacuums.
Through innovative designs and a total commitment to quality, Marco manufactures products that increase production
rates, create a safer workplace, and reduce maintenance costs. Marco’s industry experience, manufacturing
capabilities, legendary customer service, product availability, logistics services, and technology leadership is your
assurance that we deliver high quality products and services, providing the best value to you, our customer.
The Marco Difference
• Industry Experience – With Marco on your team, you have access to expertise which can only come from
decades of industry leadership. We have organized our engineering department, production specialists, customer
operations, and safety support into a “Center of Competence.” As a Marco customer, you have access to hundreds
of years of cumulative experience related to your operations.
• Manufacturing Excellence – Marco is a U.S. based, ISO 9001:2008 certified manufacturer of equipment for the
Surface Preparation and Protective Coatings industries. Marco’s engineers benchmark the industry to ensure that
we design and manufacture superior products that set the “Gold Standard” for performance, safety, and quality.
• Legendary Customer Service – Marco’s legendary customer service team is staffed by friendly, highly-trained
individuals who are focused on providing the highest level of product support, order accuracy, and customer
satisfaction.
• Product Availability – We stock over 10,000 SKU’s and have more than 45 shipping locations to serve North
American and International markets for all major brands of blasting and coating equipment. As the largest provider of
surface preparation and protective coatings equipment in the world, our inventory levels and product availability are
unmatched.
• Logistics Services – Marco’s in-house logistics team is dedicated to moving your shipment anywhere in the world.
We move more than 14,000 truckloads every year, allowing you to save on freight costs by leveraging our buying
power. Lower your process costs with a single invoice, which includes product and freight.
• Technology Leadership – Our website provides: Operator’s Manuals, Part Numbers and Schematics Guides, SDS
information, and Features & Specifications Guides, providing access to information 24/7. Our Extranet application
allows you to receive quotes and place orders online. Our Intranet maintains a complete record of your purchase
history to assist with ongoing support of your existing equipment and future purchasing decisions.
Vision Statement
Marco is the world’s premier provider ofAbrasives, Blasting, Coating, Dust Collectors, Engineered Systems, Rental,
Safety, Service, Repair, & Modernization, and Vacuums.
Mission Statement
Marco provides strong leadership and innovation to the surface preparation and protective coatings industries.
We dedicate our efforts to the continuous improvement of our products, services, processes, people, and most
importantly, the quality of our customer’s experience.
Quality Statement
Marco is committed to providing superior quality in the design, manufacturing, distribution, rental, service, and repair
of our products. Our ISO 9001:2008 certification extends throughout all operations in all locations. Continuous
improvement of our processes and supply chain Integration comprise the core of our business strategy for delivering
exceptional quality and value in all Marco products and services.
Management Philosophy
We are a company dedicated to the success of every customer and associate. We discuss, debate, challenge,
measure, and test our ideas. We will be boundless and limitless in our passion to improve. Through sound
leadership and dedicated associates, we will ensure a long term, profitable future for Marco, our associates,
customers, and suppliers.

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Company Prole . . . . . . . . . . . . . . . . . . . . . . . . . 1
Operating Instructions . . . . . . . . . . . . . . . . . . . 9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operational Requirements . . . . . . . . . . . . . . . . . 9
Operating Instructions . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Blastmaster®156E Remote Control Switch . . . 10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Disassemble and Assemble Blastmaster®
156E Remote Control Switch . . . . . . . . . . . . . . 11
Disassemble and Assemble Blastmaster®
156E Remote Control Switch - Kwikchange. . . 13
TABLE OF CONTENTS
DEFINITION OF TERMS
This is an example of a warning. This indicates a
potentially hazardous situation which, if not avoided,
could result in death or serious injury.
This is an example of a notice. This indicates policy
or practice directly related to safety of personnel or
protection of property.
This is an example of danger. This indicates an
imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This is an example of a caution. This indicates a
potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It can also be
used to alert against unsafe practices.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly Part Numbers And Schematic 15
Blastmaster®156E Remote Control Switch . . . 15
Blastmaster®156E Remote Control Switch -
Kwikchange . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . 18
Disclaimer of Warranty . . . . . . . . . . . . . . . . . . . 18
Exclusive Remedy for Warranty Claims . . . . . . 18
Limitation of Remedies. . . . . . . . . . . . . . . . . . . 18

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Failure to comply with ANY WARNING listed below could result in death or serious injury.
OSHA sets exposure limits to protect workers from exposure to respirable crystalline silica, 29 CFR 1910.1053.
Airborne dust could increase the exposure levels beyond permissible limits. Breathing dust containing silica
could cause silicosis, a fatal lung disease. Breathing dust during abrasive blasting operations, post-blast cleaning
operations, and/or servicing equipment within the abrasive blasting area may expose an individual to conditions
that could cause asbestosis, lead poisoning and/or other serious or fatal diseases. Harmful dust containing toxic
material from abrasives or surfaces being abrasive blasted can remain suspended in the air for long periods of
time after abrasive blasting has ceased. A NIOSH-approved, well-maintained, respirator designed for the specific
operation being performed must be used by anyone abrasive blasting, handling or using the abrasive, and
anyone in the area of the dust.
Contact NIOSH and OSHA offices to determine the proper respirator for your specific application. The air supplied
to the respirator must be at least Grade D quality as described in Compressed Gas Association Commodity
Specification G-7.1 and as specified by OSHA Regulation 1910.134. Ensure air filter and respirator system hoses
are not connected to non-air sources or in-plant lines that may contain nitrogen, oxygen, acetylene or other
non-breathable gases. Before removing respirator, use an air monitoring instrument to determine if the
atmosphere is safe to breathe.
You must comply with all OSHA, local, City, State, Province, Country and jurisdiction regulations, ordinances and
standards, related to your particular work area and environment. Keep unprotected individuals out of the work
area.
Abrasive blasting operators must receive thorough training on the use of abrasive resistant attire which includes:
supplied-air respirator, abrasive blasting suit, safety shoes, gloves, ear protection and eye protection. Protect the
operator and bystanders by complying with NIOSH and OSHA Safety Standards.
Inspect all equipment for wear or damage before and after each use. Failure to use Original Equipment
Manufacturer repair parts and failure to immediately replace worn or damaged components could void warranties
and cause malfunctions.
OSHA requires abrasive blasting nozzles be equipped with an operating valve, which shall be designed to be
held open only by continuous hand pressure and shall close immediately upon release of hand pressure (i.e., a
“deadman” control). The valve shall not be modified in any manner that would allow it to remain open without the
application of continuous hand pressure by the operator. Failure to comply with the above warning could result in
release of high speed abrasive and compressed air resulting in death or serious injury. OSHA 29CFR 1910.244(b)
Point the abrasive blasting nozzle only at the surface being abrasive blasted. Never point the abrasive blasting
nozzle or abrasive stream at yourself or others.
Unless otherwise specified, maximum working pressure of abrasive blasting pots and related components must
not exceed 150 psi. Exceeding maximum working pressure of 150 psi could cause the abrasive blasting pot and
components to burst. Failure to comply with the above warning could result in death or serious injury.
Never weld, grind or drill on the abrasive blasting pot (or any pressure vessel). Doing so will void ASME
certification and manufacturer’s warranty. Welding, grinding or drilling on the abrasive blasting pot (or any pressure
vessel) could weaken the vessel causing it to burst. Failure to comply with the above warning could result in death
or serious injury. (ASME Pressure Vessel Code, Section VIII, Division 1)
This equipment is not intended for use in any area that might be considered a hazardous location, as described
in the National Electric Code NFPA 70, Article 500. Use of this equipment in a hazardous location could cause an
explosion or electrocution.
Never attempt to move an abrasive blasting pot containing abrasive. Never attempt to manually move abrasive
blasting pots greater than 6.5 cubic foot capacity. Always use at least two capable people to manually move an
abrasive blasting pot on flat, smooth surfaces. A mechanical lifting device must be used if an abrasive blasting pot
is moved in any other manner.
HAZARD IDENTIFICATIONS

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HAZARD IDENTIFICATIONS
Failure to comply with ANY WARNING listed below could result in death or serious injury.
This product is not for use in wet environments. Always use a Ground Fault Interrupter Circuit (GFIC) for
all electrical power source connections. Use of this product in wet environments could create a shock or
electrocution hazard.
Frozen moisture could cause restrictions and obstructions in pneumatic control lines. Any restriction or
obstruction in the pneumatic control lines could prevent the proper activation and deactivation of the remote
control system, resulting in the release of high speed abrasive and compressed air. In conditions where moisture
may freeze in the control lines an antifreeze injection system approved for this application can be installed.
Do not cut, obstruct, restrict or pinch pneumatic control lines. Doing so could prevent the proper activation and
deactivation of the remote control system, resulting in the release of high speed abrasive and compressed air.
Use of Marco remote control switches with other manufacturer’s remote control systems could cause unintended
activation of remote control systems resulting in the release of high speed abrasive and compressed air. Only
Marco remote control switches should be used with Marco remote control systems.
Always be certain to have secure footing when abrasive blasting. There is a recoil hazard when abrasive blasting
starts that may cause user to fall and misdirect the abrasive stream at operator or bystander.
Never use an abrasive blasting pot or attachments as a climbing device. The person could slip and fall. The
abrasive blasting pot could become unstable and tip over.
For equipment manufactured by entities other than Marco, you must consult the Original Equipment Manufacturer
operator’s manuals, information, training, instructions and warnings, for the proper and intended use of all
equipment.
Flammable fumes, such as solvent and paint fumes in the work area can present an ignition or explosion hazard
if allowed to collect in adequate concentrations. To reduce conditions that could result in a fire or an explosion,
provide adequate ventilation, eliminate all ignition or spark sources, keep the work area free of debris, store
solvents and solvent contaminated rags in approved containers, follow proper grounding procedures, do not
plug/unplug power cord or turn on/off power switches when flammable fumes are present, keep a working fire
extinguisher or provide another fire suppression system in the work area. Cease all operations and correct
condition if a spark or ignition source is identified during operation.
Always depressurize the entire system, disconnect all power sources and lockout/tagout all components before
any maintenance or troubleshooting is attempted. Failure to comply with the above warning could cause electrical
shock and inadvertent activation of equipment resulting in death or serious injury.
Moving parts can present an area where crushing, pinching, entanglement or amputation may occur. Do not
place body parts or foreign objects in any area where there are moving parts.
Surfaces of heated supply tanks, drums and/or lines as well as the adjoining plumbing may become hot during
normal use. Do not touch these heated surfaces without proper protection. Deactivate and allow sufficient time for
all surfaces to cool before attempting any maintenance.
High-pressure fluid from gun, hose leaks, or ruptured components can pierce skin and can cause a serious injury
that may result in amputation. Do not point gun or spray tip at anyone or at any part of the body. Keep clear
of any leaks or ruptures. Depressurize the entire system before attempting cleaning, inspecting, or servicing
equipment.
Exposure to toxic fluids or fumes may occur during the normal operation of this system. Before attempting to
fill, use, or service this system, read SDS’s to know the specific hazards of the fluids you are using. Always use
proper Personal Protective Equipment when attempting to fill, use, or service this system.
The use of this product for any purpose other than originally intended or altered from its original design is
prohibited.
Never hang objects from the abrasive blasting pot handle. Doing so may cause the abrasive blasting pot to
become unstable and tip over.

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HAZARD IDENTIFICATIONS
Failure to comply with ANY CAUTION listed below may result in minor or moderate injury.
Static electricity can be generated by abrasive moving through the abrasive blasting hose causing a shock
hazard. Prior to use, ground the abrasive blasting pot and abrasive blasting nozzle to dissipate static electricity.
High decibel noise levels are generated during the abrasive blasting process which may cause loss of hearing.
Ensure appropriate Personal Protective Equipment and hearing protection is in use.
Failure to comply with ANY NOTICE listed below could pose a hazard to personnel or property.
See Air & Abrasive Consumption Chart for estimated abrasive consumption rates and required air flow (cubic feet
per minute). Your system must meet these minimum requirements to ensure proper function and performance.
Always use abrasive that is dry and properly screened. This will reduce the potential for obstructions to enter the
remote control system, abrasive metering valve and abrasive blasting nozzle.
Moisture build-up occurs when air is compressed. Any moisture within the abrasive blasting system will cause
abrasive to clump, clogging metering valves, hoses and nozzles. Install an appropriately sized moisture separator
at the inlet of the abrasive blasting system. Leave the moisture separator petcock slightly open to allow for
constant release of water. If insufficient volume of air exists and petcock is unable to be left open (at all times)
petcock should be opened frequently to release water.
To reduce abrasive intrusion in the air supply hose, depressurize the abrasive blasting pot before shutting off air
supply from compressor.
Inspect abrasive blasting nozzle before placing into service. Damage to abrasive blasting nozzle liner or
jacket may occur during shipping. If you receive a damaged abrasive blasting nozzle, contact your distributor
immediately for replacement. Abrasive blasting nozzles placed into service may not be returned. Abrasive blasting
nozzle liners are made of fragile materials and can be damaged by rough handling and striking against hard
surfaces. Never use a damaged abrasive blasting nozzle.
Abrasive blasting at optimal pressure for the abrasive used is critical to productivity. Example: For an abrasive
with an optimal abrasive blasting pressure of 100 psi at the abrasive blasting nozzle, one pound per square inch
of pressure loss will reduce abrasive blasting efficiency by 1.5%. A 10 psi reduction in air pressure will cause a
15% loss of efficiency. Use a Needle Pressure Gauge to identify pressure drops in your system. Consult with your
abrasive supplier for the requirements of your abrasive.
Replace abrasive blasting nozzle if liner or jacket is cracked or damaged. Replace abrasive blasting nozzle if
original orifice size has worn 1/16” or more. Determine abrasive blasting nozzle wear by inserting a drill bit 1/16”
larger than original size of abrasive blasting nozzle orifice. If the drill bit passes through abrasive blasting nozzle,
replacement is needed.

Blastmaster®156E Remote Control Switch 6
Failure to comply with ANY NOTICE listed below could pose a hazard to personnel or property.
See Air & Abrasive Consumption Chart for estimated abrasive consumption rates and required air flow
(cubic feet per minute). Your system must meet these minimum requirements to ensure proper function and
performance.
When it comes to air & abrasive mixtures, more is not necessarily better. Optimum abrasive blasting efficiency
takes place when a lean air & abrasive mixture is used. To correctly set the abrasive metering valve, begin
with the valve fully closed and slowly increase the amount of abrasive entering the airstream. As you increase
the abrasive flow, watch for a “blue flame” at the exit of the abrasive blasting nozzle. Faster cutting, reduced
abrasive consumption and lower clean up costs, are benefits of the “blue flame”.
Abrasive blasting at optimal pressure for the abrasive used is critical to productivity. Example: For an abrasive
with an optimal abrasive blasting pressure of 100 psi at the abrasive blasting nozzle, one pound per square inch
of pressure loss will reduce abrasive blasting efficiency by 1.5%. A 10 psi reduction in air pressure will cause a
15% loss of efficiency. Use a Needle Pressure Gauge to identify pressure drops in your system. Consult with
your abrasive supplier for the requirements of your abrasive.
*Abrasive consumption is based on abrasive with a bulk density of 100 lbs per Cubic Foot
Air & Abrasive Consumption Chart*
Nozzle
Orifice
Pressure at the Nozzle (PSI) Air (in cfm), Abrasive
& Compressor
Requirements
50 60 70 80 90 100 125 140
No. 2
(1/8ˮ)
11
67
2.5
13
77
3
15
88
3.5
17
101
4
18
112
4.5
20
123
5
25
152
5.5
28
170
6.2
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 3
(3/16ˮ)
26
150
6
30
171
7
33
196
8
38
216
9
41
238
10
45
264
10
55
319
12
62
357
13
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 4
(1/4ˮ)
47
268
11
54
312
12
61
354
14
68
408
16
74
448
17
81
494
18
98
608
22
110
681
25
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 5
(5/16ˮ)
77
468
18
89
534
20
101
604
23
113
672
26
126
740
28
137
812
31
168
982
37
188
1100
41
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 6
(3/8ˮ)
108
668
24
126
764
28
143
864
32
161
960
36
173
1052
39
196
1152
44
237
1393
52
265
1560
58
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 7
(7/16ˮ)
147
896
33
170
1032
38
194
1176
44
217
1312
49
240
1448
54
254
1584
57
314
1931
69
352
2163
77
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 8
(1/2ˮ)
195
1160
44
224
1336
50
252
1512
56
280
1680
63
309
1856
69
338
2024
75
409
2459
90
458
2754
101
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 10
(5/8ˮ)
308
1875
68.5
356
2140
79.5
404
2422
90
452
2690
100.5
504
2973
112
548
3250
122
663
3932
146
742
4405
165
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 12
(3/4ˮ)
432
2672
96
504
3056
112
572
3456
127
644
3840
143
692
4208
154
784
4608
174.5
948
5570
209
1062
6238
236
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
Inspect abrasive
blasting nozzle before
placing into service.
Damage to abrasive
blasting nozzle liner
or jacket may occur
during shipping. If you
receive a damaged
abrasive blasting nozzle,
contact your distributor
immediately for
replacement. Abrasive
blasting nozzles placed
into service may not
be returned. Abrasive
blasting nozzle liners
are made of fragile
materials and can be
damaged by rough
handling and striking
against hard surfaces.
Never use a damaged
abrasive blasting nozzle.
Replace abrasive
blasting nozzle if liner
or jacket is cracked
or damaged. Replace
abrasive blasting nozzle
if original orifice size
has worn 1/16” or more.
Determine abrasive
blasting nozzle wear by
inserting a drill bit 1/16”
larger than original size
of abrasive blasting
nozzle orifice. If the
drill bit passes through
abrasive blasting nozzle,
replacement is needed.
“Blue Flame”
AIR & ABRASIVE CONSUMPTION CHART

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“THE BIG PICTURE”
3
5
7
4
4
3
21
8
9
17
14
1615
13 19
18
10
20
23
21
424
27
26
25
22
28
5
3
6
11
12

Blastmaster®156E Remote Control Switch 8
Daily Pre-operation Checklist
1. Abrasive
2. Air Compressor
3. Air Hose Couplings & Gaskets
4. Air Hose
5. Safety Cable
6. Ambient Air Pump*
7. Breathing Air Filter
8. CO Monitor
9. Breathing Line
10. Climate Control Device
11. Abrasive Blasting Suit
12. Gloves
13. Abrasive Blasting Nozzle
14. Lighting System*
15. Abrasive Blasting Nozzle Holder
16. Remote Control Switch
17. Supplied-Air Respirator
18. Control Line
19. Abrasive Blasting Hose
20. Abrasive Blasting Hose
Couplings & Gaskets
21. Abrasive Metering Valve
22. Remote Control System
23. Moisture Separator
24. Abrasive Blasting Pot Exhaust
Muffler
25. Abrasive Blasting Pot
26. Abrasive Blasting Pot Screen
27. Abrasive Blasting Pot Lid
28. Aftercooler*
* Optional or alternative device.
Ask your Marco Representative
for more details.
Abrasive – Select the correct Abrasive (1) for the application. Review the SDS
(Safety Data Sheet) to ensure the correct PPE (Personal Protective Equipment)
and Environmental Controls have been selected and are in place.
Air Compressor – Select an Air Compressor (2) of adequate size to support all
equipment requirements. Refer to “Air & Abrasive Consumption Chart” for
Abrasive Blasting Nozzle (13) air consumption requirements. Before connecting
Air Hose (4), sample the air being produced by the air compressor (2) to ensure
it is free of petroleum contaminants.
Air Hose, and Air Hose Couplings & Gaskets – Select Air Hoses (4) of
sufficient size to support all subsequent volumetric requirements and with a
sufficient PSI (pound per square inch) rating. Inspect all Air Hoses (4), and Air
Hose Couplings & Gaskets (3) for damage or wear. Repair or replace damaged
or worn components.
Abrasive Blasting Hose, Abrasive Blasting Hose Couplings & Gaskets, and
Abrasive Blasting Nozzle Holder – Select an Abrasive Blasting Hose (19) that
has an inner diameter 3 to 4 times larger than your Abrasive Blasting Nozzle
(13). Inspect Abrasive Blasting Hose (19), Abrasive Blasting Hose Couplings
& Gaskets (20), and Abrasive Blasting Nozzle Holder (15) for damage or wear.
Repair or replace damaged or worn components.
Safety Cables – Install a Safety Cable (5) at each Abrasive Blasting Hose (19),
and Air Hose (4) connection points.
Aftercooler and Moisture Separator – Ensure Aftercooler (28) is positioned
on stable ground. Keep petcock drain of Moisture Separator (23) slightly open
during use. Drain both devices after each use.
Supplied-Air Respirator, Breathing Line, Breathing Air Filter, Climate
Control Device, CO Monitor, Ambient Air Pump – You MUST consult the
Operator’s Manual supplied with your Respiratory Equipment (6, 7, 8, 9,
10, 17) for ALL applicable instructions and warnings. Inspect all Respiratory
Equipment components for damage or wear. Repair or replace damaged or worn
components.
Abrasive Blasting Suit and Gloves – Select an abrasive-resistant Abrasive
Blasting Suit (11) that is slightly oversized to allow ease of movement and allows
air to flow around your body. Select abrasive-resistant Gloves (12) with a tight fit
and a long cuff that overlaps the sleeve of the Abrasive Blasting Suit (11).
Abrasive Metering Valve and Abrasive Blasting Pot – Confirm Abrasive
Blasting Pot (25) is positioned on stable ground. Inspect Abrasive Blasting Pot
(25) and Abrasive Metering Valve (21) for damage or wear. Repair or replace
damaged or worn components.
Abrasive Blasting Pot Screen and Abrasive Blasting Pot Lid – Always use
an Abrasive Blasting Pot Screen (26) when filling Abrasive Blasting Pot (25)
with Abrasive (1) to prevent debris from entering the Abrasive Blasting Pot (25).
Remove Abrasive Blasting Pot Lid (27) before operating the Abrasive Blasting
Pot (25). Install Abrasive Blasting Pot Lid (27) after use to protect the Abrasive
Blasting Pot’s (25) interior.
Remote Control System, Remote Control Switch, Control Line, – Inspect
Remote Control System (22) and Control Line (18) for damage or wear. Repair
or replace damaged or worn components. Ensure Control Line (18) fittings
connected to the Remote Control System (22) are tight and free of leaks. Ensure
Remote Control Switch (16) is functioning properly. Consult Remote Control
Switch Operator's Manual for applicable instructions.
Abrasive Blasting Pot Exhaust Muffler – Inspect Abrasive Blasting Pot
Exhaust Muffler (24) at start and end of daily use. Replace element of Abrasive
Blasting Pot Exhaust Muffler (24) per Operator's Manual instructions.
Lighting System – Ensure the Lighting System (14) is connected to a proper
power supply before use.
DAILY PRE-OPERATION CHECKLIST

Blastmaster®156E Remote Control Switch
9
OPERATING INSTRUCTIONS
Description
A remote control switch gives an operator the ability to remotely activate and deactivate
the remote control system at the abrasive blasting nozzle. An electric remote control switch
reduces the cycle time required to activate and deactivate the remote control system
compared to a pneumatic remote control switch. The reduced cycle time is most noticeable
when the operator is working at distances greater than 100 feet from the abrasive blasting
pot. The Blastmaster®156E Remote Control Switch is designed for simple maintenance
and repair. Typical applications include blast rooms, blast yards, bridges, oil refineries,
pipelines, railcar shops, shipyards, and storage tanks.
Operational Requirements
The following may cause safety hazards or reduced performance:
• Improper installation and/or maintenance of components.
• Use of anything other than hand pressure to activate remote control switch.
• Allowing anything to obstruct operation or release.
Operating Instructions
Before using:
• Set up abrasive blasting pot and remote control system. (See Operator’s Manuals.)
• Inspect electric control line and connectors for cracks, abrasion, or damage.
• Inspect Toggle Boot (1) for damage. Replace immediately if damaged.
• Test switch for free movement. Switch must return to OFF (center) position immediately
upon release.
During use:
• Activate remote control switch using thumb/finger by pushing up or down on the
Toggle Boot (1).
• To cease abrasive blasting, release Toggle Boot (1). Ensure Toggle Boot returns to
OFF (center) position.
After use:
• When abrasive blasting is concluded, inspect components for damage. Store abrasive
blasting hose with remote control switch attached in an area clear of debris and abrasive.
Use of Marco remote
control switches with
other manufacturer’s
remote control systems
could cause unintended
activation of remote
control systems
resulting in the release
of high speed media
and compressed air.
Only Marco remote
control switches should
be used with Marco
remote control systems.
Failure to comply with
the above warning
could result in death or
serious injury.
OSHA requires abrasive
blasting nozzles be
equipped with an
operating valve, which
shall be designed to
be held open only
by continuous hand
pressure and shall
close immediately
upon release of
hand pressure (i.e., a
"deadman" control).
The valve shall not
be modified in any
manner that would
allow it to remain open
without the application
of continuous hand
pressure by the
operator. Failure to
comply with the above
warning could result in
release of high speed
media and compressed
air resulting in death or
serious injury. OSHA 29
CFR 1910.244(b)
1
This product is
not for use in wet
environments. Always
use a Ground Fault
Interrupter Circuit (GFIC)
for all electrical power
source connections.
Use of this product
in wet environments
could create a shock or
electrocution hazard.
Failure to comply with
the above warning
could result in death or
serious injury.
W-519

Blastmaster®156E Remote Control Switch 10
INSTALLATION
Blastmaster®156E Remote Control Switch
Installation
1) Attach Remote Control Switch (1) to Abrasive Blasting Hose (3) using Hose Clamp (2).
2) Secure Electric Control Line (5) to Abrasive Blasting Hose (3) every 4 to 6 feet, and on
each side of the hose connections. Provide adequate slack at each connection.
3) Install a Cord Connector or Electrical Plug to the exposed end of the Electric Control
Line (5).
Pulling and dragging
abrasive blasting hose
may cause control
line and power cord
connections to separate.
Connect the control
line and power cord to
the abrasive blasting
hose every 4 to 6 feet
and on each side of the
control line connections.
Provide adequate slack
at each connection.
Use 16 gauge power
cord for lengths up
to 300 feet. To reduce
electrical resistance,
use larger gauge
electric cord.
1
2
3
5
4

Blastmaster®156E Remote Control Switch
11
MAINTENANCE
Disassemble and Assemble Blastmaster®156E Remote Control Switch
Maintenance of the Blastmaster®156E Remote Control Switch is limited to the daily
cleaning and the immediate replacement of damaged or worn parts.
The use of this product
for any purpose other
than originally intended
or altered from its
original design is
prohibited. Failure to
comply with the above
warning could result in
death or serious injury.
Always depressurize the
entire blasting system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the
above warning could
cause electrical
shock and inadvertent
activation of equipment
resulting in death or
serious injury.
Note: Anytime a switch is being replaced, the cord supplied with switch should be replaced
and discarded.
Disassemble:
1) Disconnect switch from power source.
2) Remove Cap (1) by turning counter-clockwise.
Note: Note that terminals 1, 2 and 3 on Switch (2) and the threads in Cap (1) have silicone
on them. This silicone must be removed from all surfaces.
3) Cut cord (5) at location (7).
4) Loosen Screws (6) by rotating counterclockwise four full turns.
5) Remove Boot (4) by unscrewing counterclockwise.
6) Remove Switch (2) by pushing on end of exposed Toggle (8).
7) Remove any residual silicone.
Assemble:
1) Install Electric Control Line (5) into Switch Body (3).
2) Taking switch (2) in hand, slide switch into place with the groove on Threads (9) facing
down. Pull Electric Control Line through Switch Body until Switch (2) seats in Switch
Body.
3) Install Jumper Cable (13) across terminals #1 and #3.
Note: When Switch (2) is properly seated, Terminal #1 (10) will be on top.
4) To connect cord, the white wire should be connected to Terminal #2 (11) and the black
wire connected to Terminal #3 (12). Tighten screws (10-–12).
5) Decrease the amount of excess wire located in the switch cavity by pulling on cord (5)
until all of the excess has been removed.
6) Tighten Screws (6) by rotating clockwise four full turns.
7) Install boot (4) by rotating clockwise on Threads (9), making sure that the boot is on
snugly. Over-tightening will cause damage to the boot and nullify its effectiveness. One
full turn of the boot after it has reached its position should suffice.
8) Check for electrical continuity by connecting White And Black wires to a flashlight
continuity checker, then depressing boot. Light should come on. Repeat this procedure
by raising boot. Light should come on. Under no circumstances should light come on
when boot is in the center (neutral) position.
Note: If the switch is not working properly, recheck steps 1 through 4.
9) Apply a sufficient amount of silicone to completely cover to terminals 1, 2, & 3. Apply
a small amount of silicone to female threads in cap (1) and install cap (1) by rotating
clockwise approximately 3 times.

Blastmaster®156E Remote Control Switch 12
MAINTENANCE
Disassemble and Assemble Blastmaster®156E Remote Control
Switch (cont.)
1
2
3
3
2
1
2
3
4
5
6
7
8
9
10
11
12
13

Blastmaster®156E Remote Control Switch
13
MAINTENANCE
Disassemble and Assemble Blastmaster®156E Remote Control
Switch - Kwikchange
The use of this product
for any purpose other
than originally intended
or altered from its
original design is
prohibited. Failure to
comply with the above
warning could result in
death or serious injury.
Always depressurize the
entire blasting system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the
above warning could
cause electrical
shock and inadvertent
activation of equipment
resulting in death or
serious injury.
Maintenance of the Blastmaster®156E Remote Control Switch is limited to the daily
cleaning and the immediate replacement of damaged or worn parts.
Disassemble:
1) Disconnect switch from power source.
2) Remove Cap (3) by turning counter-clockwise.
3) Cut cord (2 at location (8).
4) Loosen Screws (1) by rotating counterclockwise four full turns.
5) Remove Boot (6) by unscrewing counterclockwise.
6) Remove Switch (4) by pushing on end of exposed Toggle (9).
7) Remove any residual silicone.
Assemble:
1) Install Electric Control Line (2) into Switch Body (5).
2) Taking switch (4) in hand, slide switch into place with the groove on Threads (7) facing
down. Pull Electric Control Line through Switch Body (5) until Switch seats in Switch
Body.
3) Decrease the amount of excess wire located in the switch cavity by pulling on cord (2)
until all of the excess has been removed.
4) Tighten Screws (1) by rotating clockwise four full turns.
5) Install boot (6) by rotating clockwise on Threads (7), making sure that the boot is on
snugly. Over-tightening will cause damage to the boot and nullify its effectiveness. One
full turn of the boot after it has reached its position should suffice.
6) Check for electrical continuity by connecting White And Black wires to a flashlight
continuity checker, then depressing boot. Light should come on. Repeat this procedure
by raising boot. Light should come on. Under no circumstances should light come on
when boot is in the center (neutral) position.
Note: If the switch is not working properly, recheck steps 1 through 4.
7) Apply a small amount of silicone to female threads in cap (3) and install cap by rotating
clockwise approximately 3 times.
1
8
4
6
5
2
79
3

Blastmaster®156E Remote Control Switch 14
TROUBLESHOOTING
Use 16 gauge power
cord for lengths up
to 300 feet. To reduce
electrical resistance,
use larger gauge
electric cord.
Always depressurize the
entire blasting system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the
above warning could
cause electrical
shock and inadvertent
activation of equipment
resulting in death or
serious injury.
If the Blastmaster®156E Remote Control Switch does not function properly, check the
following:
SYMPTOM (Cause) ACTION
Control Switch operates in only
one direction
(Debris or foreign object, damaged
Toggle Boot, or Toggle Switch.
Clean around Toggle boot. Remove any
debris.
Replace Toggle Boot if damaged.
Replace Blastmaster®156E Remote Control
Switch or repair using the repair kit.
Remote Control System fails to
operate when Control Switch is
activated
(Power interrupted, debris or foreign
object, damaged Toggle Switch, Remote
Control System failure)
Inspect all electric control lines and
connections.
Clean around Toggle Boot. Remove any
debris.
Replace Toggle Boot if damaged.
Replace Blastmaster®156E Remote Control
Switch or repair using the repair kit.
See remote control system Operator's
Manual.
Switch DOES NOT return to
OFF (center) position
(Debris or foreign object, damaged
Toggle Boot or Toggle Switch.)
Clean around Toggle Boot. Remove any
debris.
Replace Blastmaster®156E Remote Control
Switch or repair using the repair kit.

Blastmaster®156E Remote Control Switch
15
DATE TYPE OF SERVICE PART NUMBER
MAINTENANCE NOTES

Blastmaster®156E Remote Control Switch 16
MAINTENANCE NOTES
DATE TYPE OF SERVICE PART NUMBER

Blastmaster®156E Remote Control Switch
17
DATE TYPE OF SERVICE PART NUMBER
MAINTENANCE NOTES

Blastmaster®156E Remote Control Switch 18
LIMITED WARRANTY
Seller warrants to the original purchaser that the Product covered by this Limited Warranty will remain free from
defects in workmanship or material under normal commercial use and service for a period of one year from the
date of shipment to the original Purchaser. This Warranty shall not apply to defects arising, in whole or in part,
from any accident, negligence, alteration, misuse or abuse of the Product, operation of the Product which is not
in accordance with applicable instructions or manuals or under conditions more severe than, or otherwise
exceeding, those set forth in the written specifications for the Product, nor shall this Warranty extend to repairs or
alterations of the Product and/or any maintenance part by persons other than Seller or Seller’s authorized
representatives. This warranty does not apply to accessory items. Further, this Warranty does not apply to
damage or wear to the surface finish or appearance of the Product or normal wear and tear to the Product. This
Warranty is limited to a purchaser who purchases the Product either directly from the Seller or from one of
Seller’s “Authorized Distributors”.An Authorized Distributor is a Seller approved distributor that purchases the
Product directly from the Seller for the sole purpose of re-selling the Product at retail, without any use or
modifications whatsoever, to an end-purchaser. This warranty is specifically non-assignable and non-transferable.
DISCLAIMER OF WARRANTY
The foregoing Limited Warranty is exclusive and is in lieu of all other warranties, whether oral or written and
whether express, implied, or statutory. SELLER HEREBY DISCLAIMSALL OTHER WARRANTIES, INCLUDING
BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FORA PARTICULAR
PURPOSE ANDALL SUCH OTHER WARRANTIES ARE HEREBY EXCLUDED ANDARE INAPPLICABLE TO
THE PRODUCT. Seller makes no warranties or representations of any kind concerning respirators, or equipment
made by other manufacturers. Seller’s agents and representatives are not authorized to offer any further
warranties.
EXCLUSIVE REMEDY FOR WARRANTY CLAIMS
THE SOLEAND EXCLUSIVE REMEDYUNDER THE FOREGOING LIMITED WARRANTY,AND TO THE EX-
TENTPERMITTEDBYLAW,ANYWARRANTYORCONDITION IMPLIEDBYLAW,COVERINGTHIS PROD-
UCT SHALLBE,AT THE SELLER’S OPTION,THE REPAIR OR REPLACEMENT,FREE OF CHARGE, F.O.B.
POINTOFMANUFACTURE,OFANYDEFECTIVEPARTORPARTSOFTHEPRODUCTTHATWEREMANU-
FACTURED BY SELLER,AND WHICH ARE RETURNED TO SELLER AT SELLER’S PRINCIPAL PLACE OF
BUSINESS , POSTAGE PREPAID BY THE PURCHASER. THIS SOLEAND EXCLUSIVE REMEDY IS CON-
DITIONEDUPONPURCHASER’SPROMPTWRITTENNOTICETOSELLERATSELLER’SPLACEOFBUSI-
NESSTHATADEFECTHASBEENDISCOVERED,TOGETHERWITHAREASONABLYDETAILEDDESCRIP-
TION OF THE DEFECTIN THE PRODUCT, PROOF OF PURCHASE OFTHE PRODUCT,AND THE MODEL
ANDIDENTIFICATIONNUMBEROFTHEPRODUCTWITHINTHIRTY(30)DAYSAFTERDISCOVERYOFTHE
DEFECT,OTHERWISESUCHCLAIMSSHALLBEDEEMEDWAIVED.NOALLOWANCEWILLBEGRANTED
FORANYREPAIRS ORALTERATIONS MADE BY PURCHASER OR OTHERS WITHOUT SELLER’S PRIOR
WRITTEN CONSENT. IF SUCH NOTICE IS TIMELY GIVEN, SELLER WILL HAVE THE OPTION TO EITHER
MODIFY THE PRODUCT OR COMPONENT PART THEREOF TO CORRECT THE DEFECT, REPLACE THE
PRODUCT OR PART WITH COMPLYING PRODUCTS OR PARTS, OR REFUND THE AMOUNT PAID FOR
THE DEFECTIVE PRODUCT,ANY ONE OF WHICH WILLCONSTITUTE THE SOLE LIABILITY OF SELLER
ANDFULLSETTLEMENTOFALLCLAIMS.INNOEVENTSHALLSELLERBELIABLEFORANYOBLIGATION
GREATER THANTHE ORIGINAL PURCHASE PRICE OFTHE PRODUCT UNDERTHIS WARRANTY. PUR-
CHASERSHALLAFFORDSELLERPROMPTANDREASONABLEOPPORTUNITYTOINSPECTTHEPROD-
UCTFORWHICHACLAIMISMADE.THESOLEPURPOSEOFTHEFOREGOINGSTIPULATEDEXCLUSIVE
REMEDYSHALLBETOREPAIRORREPLACEDEFECTIVEPRODUCTSORCOMPONENTSTHEREOF,OR
TO REFUND PURCHASERTHE PURCHASE PRICE THEREOF. THIS STIPULATED EXCLUSIVE REMEDY
SHALLNOTBEDEEMED TO HAVEFAILED OFITSESSENTIALPURPOSE SOLONGASSELLER ISWILL-
INGANDABLETOREPAIRORREPLACETHEDEFECTIVEPARTSORREFUNDTHEPURCHASEPRICEIN
ACCORDANCEWITHTHETERMSHEREOF.PRODUCTSTHATHAVEBEENREPAIREDORREPLACEDUN-
DERTHISWARRANTYDONOTRECEIVEANEWWARRANTYANDAREONLYCOVEREDBYTHEREMAIN-
ING PORTION OF THE ORIGINAL WARRANTY.
LIMITATION OF REMEDIES
The foregoing stipulated exclusive remedy is in lieu of all other remedies for breach of contract, warranty, and/or
tort or otherwise. Seller shall not be liable, either directly or indirectly, for any consequential, incidental or special
losses or damages of Purchaser, including but not limited to the Purchaser’s expenses for downtime or for making
up downtime, damages for which the Purchaser may be liable to other persons and/or entities, damages to prop-
erty, and injury to or death of any persons and/or any claims for incidental or consequential damages, including
but not limited to loss of prots, regardless of whether Seller has been informed of the possibility of such dam-
ages. Seller neither assumes, nor authorizes any person to assume for it, any other liability in connection with the
sale or use of any Products covered by the foregoing Warranty and Disclaimers, and there are no oral agreements
relating to remedies which are collateral to or which a󰀨ect this limitation.
ADDITIONAL
TECHNICAL DATA
The associations listed
below oer information,
materials and videos
pertaining to abrasive
blasting and safe
operating practices.
• American Society
for Testing and
Materials (ASTM)
100 Barr Harbor Drive
West Conshohockon,
PA 19428-2959
Phone: [phone]
FAX: [phone]
www.astm.org
• Occupational
Safety & Health
Administration (OSHA)
United States
Department of Labor
200 Constitution Avenue
Washington, DC 20210
Phone: (800) 321-OSHA
[phone]
www.osha.gov
• The National Board
of Boiler & Pressure
Vessel Inspectors
1055 Crupper Avenue
Columbus, Ohio 4322
Phone: [phone]
FAX: [phone]
www.nationalboard.org
• National Association
of Corrosion Engineers
(NACE)
1440 South Creek Drive
Houston, TX 77084-4906
Phone: [phone]
FAX: [phone]
www.nace.org
• The Society
for Protective
Coatings (SSPC)
40-24th Street, 6th Floor
Pittsburgh, PA 15222-4656
Phone: [phone]
FAX: [phone]
www.sspc.org
• American National
Standards Institute
(ANSI)
1899 L Street, NW, 11th Floor
Washington, DC 20036
Phone: [phone]
FAX: [phone]
www.ansi.org

Part #1090139_6/20/2019
Marco®and Blastmaster®are registered trademarks of Marco Group International Opco. LLC.
All other brand names or marks are used for identication purposes and are trademarks of their respective owners.
•
3425 East Locust Street
Davenport, IA 52803
ph: 800.BLAST.IT (800.252.7848)
ph: 563.324.2519
fax: [phone]
40+ NATIONWIDE SHIPPING LOCATIONS
Marco Regional Branch O󰀩ces
and Shipping Locations Direct Shipping Locations
CONTACT MARCO
800.BLAST.IT
(800.252.7848)
563.324.2519
FAX: [phone]
WWW.MARCO.US
[email protected]
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