Blastrac 2-45D Operating Instructions Manual Download

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Service Manual

Side shift & adapter 2-45D

Technical data

1.1 Rating

Unit / designation

Blastrac

side shift & machine adapter

Machine type

: Side shift & machine adapter 2-45D

Manufacturer :

Blastrac BV

Utrechthaven 12

NL-3433PN Nieuwegein

THE NETHERLANDS

1.2 Unit

specifications

Dimensions:

Side shift & adapter 2-45D

Length

1050 mm

Width

2350 mm

Height

2000 mm

Weight

1000 kg

Angular movement:

Fig. 1.1

The hydraulic cylinder of the machine adapter can swivel the

Blastrac 2-45D

blast cleaning machine 8° up and 8° down.

Summary of Contents for 2-45D

Page 1: ...Operating Instructions 2 45D MAN 2 45D EN Freightliner...

Page 2: ...Safety Instructions General Transport Initial Operation Operation Maintenance Electrical Hydraulic Systems Fault Diagnosis Spare parts Design and specificati ons are subject to change w ithout notice...

Page 3: ......

Page 4: ...rating 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...

Page 5: ...n 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...

Page 6: ...00 m h Dust hose connection 2 x 150 mm Recommended abrasive Shot 460 550 Abrasive consumption 0 1 0 5 kg m Recommended filter unit 2 45 TDC 1 3 Operative range and correct usage The 2 45D is exclusive...

Page 7: ...last 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 o...

Page 8: ...d 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 opera...

Page 9: ...hown 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 in...

Page 10: ...g 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 I...

Page 11: ...g 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 noti...

Page 12: ...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 M...

Page 13: ...nt 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...

Page 14: ...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 Al...

Page 15: ...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 t...

Page 16: ...ty 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 Ab...

Page 17: ...d 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 recurr...

Page 18: ...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 sea...

Page 19: ...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 co...

Page 20: ...or 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 wh...

Page 21: ...hine 2 45D Dust hose Operating instructions 2 x Machine adapter Tow behind magnet sweeper 2 45TBS 3 6 Description Fig 3 1 1 1 Separator incl hopper 6 Feed spout 2 Blast wheel motor 7 Blasthead rubber...

Page 22: ...acceleration the abrasive is thrown onto the surface at high speed by the blast wheel Once the abrasive has impacted on the surface it rebounds into a recovery duct The recovery duct deflects the abr...

Page 23: ...placed in a protective housing lined with replaceable wear parts The blast wheels are driven by two hydraulic motors Fig 3 3 Around the centre of the blast wheel there is the impeller feeding dosed qu...

Page 24: ...functions as a second separator for bigger particles and feeds the cleaned abrasive back to the abrasive storage hopper Two wire meshes are fitted to prevent any coarse contaminants from getting into...

Page 25: ...The seals are employed to seal the blasting area in a way to avoid leakage of any abrasive The correct height adjustment of the magnetic seals 16 20 mm is very important for optimum functionability of...

Page 26: ...surface The brushes are clamped between two guides This assembly is pressed on the floor by two springs inside the brush housing The floating side brushes are kept inside the brush housing by two scre...

Page 27: ...unit Recommended blower 2 45 TDC Motor output 22 kW Air throughput 5400 m h Dust hose 2 x 8 m Diameter 150 mm The correct height adjustment of the machine 16 20 mm is of utmost importance There must...

Page 28: ...he air enters the separator separates the dust from the abrasive and transports the dust to the outlet opening The separator cover must be closed air tight in order to grant an optimum performance of...

Page 29: ...herical abrasive The machine 2 45D has been especially designed to be operated with Blastrac abrasive The Blastrac abrasive is of very high quality and owns the rebouncing ability required for the eff...

Page 30: ...ible coatings on parking house decks removes markings on roads and runways The effectiveness of the 2 45D depends on the rebound effect which ensures that the abrasive can be re used Please take into...

Page 31: ...2 45D Operating Instructions Transport 1 Contents Chapter 4 4 1 General notes 4 2 Transport 4 3 Operation conditions 4 4 Operation 4 5 Unit specifications...

Page 32: ...transporting the machine proceed in such a manner that damage due to the effects of the use of force or incorrect loading and unloading is avoided Remove the abrasive from the machine before it is tr...

Page 33: ...loor joints are no barriers for the machine 4 4 Operation The machine is operated in accordance with the instructions given in Chapter 5 Initial operation Whenever the machine is not used for blast cl...

Page 34: ...2 45D Operating Instructions Initial operation 1 Contents Chapter 5 5 1 Preparations for initial operation 5 2 Initial operation...

Page 35: ...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 Regular inspection is important in order to avoid d...

Page 36: ...abrasive in the storage hopper Refill if necessary Before start up the operating personnel must be familiar with the safety regulations given in this manual and with the service manual supplied with t...

Page 37: ...dy 5 2 Initial operation 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 fitti...

Page 38: ...her disturbance Find out the cause of the disturbance and if necessary contact your Blastrac customer service engineer Start driving in the working direction and set the travel speed Fig 5 2 When blas...

Page 39: ...xceeding the full load value means overloading of the hydraulic system whereas an indication below the full load value shows that there is not enough abrasive fed to the blast wheel If necessary re ad...

Page 40: ...5D Operating Instructions Operation 1 Contents Chapter 6 6 1 Operation 6 2 Hydraulic system 6 3 Switching off the machine 6 4 What to do if a fault occurs 6 5 Safety shutdown 6 6 Restarting after a fa...

Page 41: ...chieved by varying the advancing speed during blast cleaning 6 2 Hydraulic system Please contact Blastrac for a complete manual describing all controls and settings 6 3 Switching off the machine Shut...

Page 42: ...ty off position After that start looking for the defect 6 5 Safety shutdown The machine must be put to its safety off position before starting repair works See Chapter 2 Safety instructions 6 6 Restar...

Page 43: ...Operating Instructions 2 45D Operation 4...

Page 44: ...nts Chapter 7 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 The blast pattern 7 5 Setting the blast pattern 7 6 Setting the control cages 7 7 Wear parts 7 8 Changing the li...

Page 45: ...hen the indicated number of working hours is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a year Due to different w...

Page 46: ...ng work Check the hose to the filter for damages Check the electric connections for sediments of dirt or foreign bodies Remove foreign bodies and dust deposits Check the hydraulic hoses for damages an...

Page 47: ...fill the hopper with abrasive Watch the level and mixture of abrasive in the abrasive storage hopper The mixture should be nearly clean If necessary regulate the air flow with the blower throttle Chec...

Page 48: ...tion and tension of the V belts Adjust or replace if necessary Fill up the bearing unit of the blower with grease Depending on the use of the machine pump two to three strokes of grease at both sides...

Page 49: ...nance or which are required to replace wear parts If you replace parts yourself for specific reasons the following instructions and work sequence have to be observed You should also stock all spare or...

Page 50: ...djustment of the control cage and thus of the blast pattern is the most important factor for optimum working with the 2 45D blast cleaning machine Incorrect adjustment of the control cage results in v...

Page 51: ...last wheel motor is designed for a long service life Damages to the blast wheel motor can be detected by unusual noises or functional failure of the hydraulicic motor In this case notify our service d...

Page 52: ...of the abrasive affects the blast pattern With every exchange of abrasive the blast pattern must be re adjusted Position of the control cages The correct adjustment of the control cages is the most im...

Page 53: ...rent weights and frictional resistance This means that you must never use different types of abrasive at the same time The adjustment can be carried out as follows Determine the upper and lower window...

Page 54: ...rol cage anti clockwise for 3 6 mm If the right side is warmer turn the lower edge of the control cage clockwise for 3 6 mm Looking from the front side of the machine onto the right hand control cage...

Page 55: ...Operating Instructions 2 45D Maintenance 12 7 7 Wear parts The blast wheel parts Fig 7 3 1 Control cage 2 Impeller 3 Blades set of 6 4 Blast wheel...

Page 56: ...45D Operating Instructions Maintenance 13 The liners Fig 7 4 1 Top liner outer 2 Top liner inner 3 Side liner 4 Rebound side liner LH 5 Rebound top liner 6 Rebound bottom liner 7 Rebound side liner R...

Page 57: ...rs 2 Remove the top liners 3 Loosen the fastening screws securing the left and the right hand rebound side liners and take these liners out of the blast housing 4 Loosen the fastening screws securing...

Page 58: ...ller 4 Clean the blast wheel and the blades with air Through the opening at the top of the blast housing use a wooden or brass drift to tap out all six blades from the blast wheel towards the centre o...

Page 59: ...2 45D Operating Instructions Electrical hydraulic systems Contents Chapter 8 8 1 Circuit diagram 8 2 Hydraulic diagram...

Page 60: ...cal hydraulic systems 8 1 Circuit diagram Please contact Blastrac for a complete manual containing the circuit diagram of the electrical system Contact Blastrac to get more details about the electrica...

Page 61: ...al hydraulic systems 8 2 Hydraulic diagram Please contact Blastrac for a complete manual containing the hydraulic diagram of the hydraulic system Contact Blastrac to get more details about the hydraul...

Page 62: ...2 45D Operating Instructions Fault diagnosis 1 Contents Chapter 9 9 1 Fault diagnosis blast machine 9 2 Fault diagnosis hydraulic and electrical system...

Page 63: ...e Incorrect setting or control cages Move the blast head of the blast machine onto a 5 8 mm thick steel plate and blast for 45 seconds at full power without moving the machine from the spot Move the m...

Page 64: ...ter unit cartridges and seals Adjust the airflow so that the abrasive doesn t drop dead on the surface but make sure that not too much abrasive is sucked into the filter unit Building up of abrasive a...

Page 65: ...using and not the surface to be blasted Adjust the blast pattern Every surface to be treated is different and has its own blast cleaning characteristics Blastrac is always available to help you choosi...

Page 66: ...ctions Spare parts 1 Contents Chapter 10 10 1 Blast wheel unit 10 2 Blast wheel drive 10 3 Blast housing and liners 10 4 Base seals 10 5 Shot valve 10 6 Separator 10 7 Separator seals 10 8 Rebound ple...

Page 67: ...3966B Cage clamp 4 2 500 1010 Control cage 2 3 RB100A 24 Control cage adjuster 2 4 RB100A 191 Front plate 2 5 BE0199 Impeller bolt M12x40 2 6 BE0042 Impeller washer M12 2 7 600 1015 Impeller 2 8 500 1...

Page 68: ...435 Belt guard 2 2 RB165 1 HTD Belt 2 3 RB165 3 Taper lock bush 2 4 RB165 2 HTD pulley 2 5 E02433 Blast motor fill up plate 2 6 E02178 Wheel motor protection plate 2 7 RB165 Hydraulic motor 2 8 E01907...

Page 69: ...using cover 1 2 RB100A5 3 Top outer liner 2 3 RB100A5 2 Top inner liner 2 4 E02430 Blast housing 2 45D 1 5 RB100A 25 Liner fixing block 4 6 E02343 Airflow adjuster 1 7 RB100A5 4 Side liner 2 8 RB100A5...

Page 70: ...Base seals Fig 10 4 Item Part no Description QTY 1 E10297 Brush housing 2 2 RB117 Side magnet 4 3 RB118A Front magnet 2 4 E10310 Front brush 3 5 E02198 Rear brush 1 6 E10278 Side brush outer 2 7 E1027...

Page 71: ...ount bracket 1 2 E01839RH Magnetic valve RH 1 3 E01839LH Magnetic valve LH 1 4 RB100A 19 Clamping ring 2 5 RB100A 20 Feed spout seal 2 6 RB100A 10 Feed spout 2 7 E02121 Valve lever 2 8 E01838 Linear a...

Page 72: ...RB100A3 31 Hydraulic motor 1 5 RB100A31B Separator 1 6 RB100A3 32 Belt pulley 1 7 RB100A3 34 Drum pulley 1 8 222 2301 V Taper lock bush 1 9 RB100A3 350 Taper lock bush 1 10 RB100A3 360 Belt 3 11 RB100...

Page 73: ...r seals Fig 10 7 Item Part no Description QTY 1 E10309 Rubber air guide 2 2 RB100A34 9 Deflector seal 1 3 RB100A3 340 Top seal strip 1 4 RB100A3 330 Top seal edge 2 6 E10292 Side seal magnetic drum 2...

Page 74: ...3 E02196 Steering bracket 1 4 E02202 Locking pin 1 5 Ironware M8x16 bolt DIN 933 1 6 E02201 Steering bracket ring 1 7 E02181 Transport castor bracket 1 8 E02200 Steering bracket bolt 1 9 E02203 Lockin...

Page 75: ...Service Manual Side shift adapter 2 45D MAN SA2 45D EN...

Page 76: ...l Data Safety Instructions General Transport Initial Operation Operation Maintenance Hydraulic System Fault Diagnosis Spare parts Design and specificati ons are subject to change w ithout notice Novem...

Page 77: ...Side shift adapter 2 45D Service Manual Technical data Contents Chapter 1 1 1 Rating 1 2 Unit specifications 1 3 Operative range and correct usage 1 4 Advice for operators 1...

Page 78: ...dapter 2 45D Manufacturer Blastrac BV Utrechthaven 12 NL 3433PN Nieuwegein THE NETHERLANDS 1 2 Unit specifications Dimensions Side shift adapter 2 45D Length 1050 mm Width 2350 mm Height 2000 mm Weigh...

Page 79: ...t be liable for damage resulting from such incorrect usage In these cases the user assumes all risks 1 4 Advice for operators In accordance with the accident prevention regulations for blast cleaning...

Page 80: ...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...

Page 81: ...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 t...

Page 82: ...ore 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 c...

Page 83: ...atutory 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 De...

Page 84: ...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 side shift and machine adapter in the Safety of...

Page 85: ...ork 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 engineering regulations...

Page 86: ...ponsible for compliance with the safety regulations during operation and maintenance of safety devices supplied with the machine adapter as well as the provision of appropriate additional safety devic...

Page 87: ...that are sized and marked in accordance with the overall power consumption of the side shift and machine adapter The hydraulic equipment for the plant must be inspected regularly Please note in partic...

Page 88: ...Side shift adapter 2 45D Service Manual 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...

Page 89: ...stand it fully The supplied side shift and machine adapter 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...

Page 90: ...clothing 3 3 Hydraulic connections Pressure Swivel cylinder max 250 bar Lift cylinder max 210 bar Please contact Blastrac to get more details about requirements for the 2 45D side shift and machine a...

Page 91: ...dapter Machine adapter for 2 45D blast cleaning machine Side shift for 2 45D blast cleaning machine Lift unit for 2 45D blast cleaning machine Adapter frame Service manual 2 x 3 6 Description Fig 3 1...

Page 92: ...ervice Manual General 5 Fig 3 2 1 Machine adapter complete 6 Lift cylinder bolt 2 Side shift unit complete 7 M24 nut SLW PW 3 Split pin 8 Lift unit complete 4 Plain washer 9 Adapter frame 5 Hydraulic...

Page 93: ...6 The Blastrac side shift and machine adapter is designed to mount a 2 45D blast cleaning machine on a truck Fig 3 3 Because the side shift and machine adapter is only designed for the above configura...

Page 94: ...Side shift adapter 2 45D Service Manual Transport 1 Contents Chapter 4 4 1 General notes 4 2 Transport 4 3 Operation 4 4 Unit specifications...

Page 95: ...When transporting the 2 45D blast machine proceed in such a manner that damage due to the effects of the use of force or incorrect loading and unloading is avoided The side shift and machine adapter i...

Page 96: ...y precautions and accident prevention guidelines are to be followed 4 3 Operation The side shift and machine adapter is operated in accordance with the instructions given in Chapter 5 Initial operatio...

Page 97: ...Side shift adapter 2 45D Service Manual Initial operation 1 Contents Chapter 5 5 1 Preparations for initial operation 5 2 Initial operation...

Page 98: ...or floor joints are no barriers for the machine and its adapter Regular inspection is important in order to avoid downtimes Carry out the following checks before any start up Check whether all side sh...

Page 99: ...Side shift adapter 2 45D Service Manual Initial operation 3 Start driving in the working direction and set the travel speed Fig 5 1 Alter the travel direction only after a full standstill...

Page 100: ...r 2 45D Service Manual Operation 1 Contents Chapter 6 6 1 Operation 6 2 Hydraulic system 6 3 What to do if a fault occurs 6 4 Safety shutdown 6 5 Restarting after a fault 6 6 Measures before and after...

Page 101: ...ok in the hydraulic system manual for a complete description of all controls and settings 6 3 What to do if a fault occurs Irrespective of the following information the local safety regulations are va...

Page 102: ...6 Measures before and after long standstills Standstill of the side shift and machine adapter for a maximum of 3 months Before a long standstill period Protect the hydraulic components from moisture h...

Page 103: ...Side shift adapter 2 45D Service Manual Maintenance 1 Contents Chapter 7 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 Replacement parts...

Page 104: ...ion When the indicated number of working hours is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a year Due to differ...

Page 105: ...gn bodies Remove foreign bodies and dust deposits Check all screw connections for tight seat Check whether all side shift and machine adapter parts are assembled safely and correctly Annually or every...

Page 106: ...which are required to replace wear parts If you replace parts yourself for specific reasons the following instructions and work sequence have to be observed You should also stock all spare or wear pa...

Page 107: ...first Fig 7 1 Every year or every 150 hours 1 1 M16 x 35 SLW PW 8x 1 6 Spring lock washer 2x 1 2 Split pin 2x 1 7 M24x70 bolt 2x 1 3 Swivel bolt 1x 1 8 Load bearing 6x 1 9 M14x40 SLW PW 16x 1 5 Spacer...

Page 108: ...one or two years or every 150 or 300 hours whatever comes first Fig 7 2 Every year or every 150 hours 1 1 M24x80 PW 2x 1 2 M24 SLW PW 2x Every two years or every 300 hours 2 1 Split pin 4x 2 3 Lift c...

Page 109: ...Side shift adapter 2 45D Service Manual Hydraulic system Contents Chapter 8 8 1 Hydraulic diagram...

Page 110: ...ystem 8 1 Hydraulic diagram Please look at the hydraulic manual for a complete description and containing the hydraulic diagram of the hydraulic system Contact Blastrac to get more details about the h...

Page 111: ...Side shift adapter 2 45D Service Manual Fault diagnosis Contents Chapter 9 9 1 Fault diagnosis side shift and machine adapter 9 2 Fault diagnosis hydraulic system 1...

Page 112: ...nosis Possible cause Remedy Too much free movement in adapter Too much play on bearings Replace bearing bushes immediately Too much play on bolts Replace bolts immediately 9 2 Fault diagnosis hydrauli...

Page 113: ...Side shift adapter 2 45D Service Manual Spare parts Contents Chapter 10 10 1 Side shift and adapter 10 2 Machine adapter 10 3 Side shift unit 10 4 Lift unit 10 5 Adapter maintenance kits 1...

Page 114: ...complete 1 2 E02323 Side shift unit complete 1 3 ISO 1234 5 x 63 Split pin 4 4 ISO 7091 M33 Plain washer 4 5 E02126 Hydraulic cylinder 1 6 E02158 Lift cylinder bolt 2 7 Ironware M24 nut SLW PW 2 8 E0...

Page 115: ...on head bolt SLW PW 8 3 RB317 Bearing bush 6 4 RB104A3L Swivel bracket LH 1 5 E02369 Swivel bolt 1 6 RB136A 1 Washer for bolt 2 7 ISO 1234 5 x 63 Split pin 2 8 RB104A5 Force bar 1 9 DIN 933 M12 x 40 H...

Page 116: ...ate 1 20 RB104A6 Bolt welded 2 21 E02156 Spacer 2 22 DIN 127 A 24 Spring lock washer 4 23 DIN 931 M24 x 70 Hexagon head bolt 2 24 350 4005 S Hydraulic motor 1 25 DIN 933 M12 x 45 Hexagon head screw PW...

Page 117: ...n head screw SLW PW 6 2 E02152 Mount bracket RH 1 3 E02151 Mount bracket LH 1 4 E02347 Hose guide 150 2 5 E02173 Sprocket profile 1 6 E02154 Rigid caster 2 7 E02274 Transport caster bracket 2 8 E02124...

Page 118: ...Service Manual Side shift adapter 2 45D Spare parts 6 10 4 Lift unit Fig 10 4 Item Part no Norm Description QTY 1 E02325 Lift unit 1 2 E02159 Manifold mount plate 1 3 E02282 Manifold roof 1...

Page 119: ...maintenance kit 7 Every year or every 150 hours 1 1 M16 x 35 SLW PW 8x 1 6 Spring lock washer 2x 1 2 Split pin 2x 1 7 M24x70 bolt 2x 1 3 Swivel bolt 1x 1 8 Load bearing 6x 1 9 M14x40 SLW PW 16x 1 5 Sp...

Page 120: ...e or two years or every 150 or 300 hours whatever comes first Fig 10 6 E02423 Adapter maintenance kit 6 Every year or every 150 hours 1 1 M24x80 PW 2x 1 2 M24 SLW PW 2x E02421 Adapter maintenance kit...

Page 121: ...Operating Instructions 2 45TDC MAN 2 45TDC EN Freightliner...

Page 122: ...ta Safety Instructions General Transport Initial Operation Operation Maintenance Electrical Hydraulic Systems Fault Diagnosis Spare parts Design and specificati ons are subject to change w ithout noti...

Page 123: ...2 45TDC Operating Instructions Technical data Contents Chapter 1 1 1 Rating 1 2 Unit specifications 1 3 Operative range and correct usage 1 4 Hydraulic power pack PTO 1 5 Machine type designation 1...

Page 124: ...lastrac BV Utrechthaven 12 NL 3433PN Nieuwegein THE NETHERLANDS 1 2 Unit specifications Dust collector dimensions Dust collector incl frame Dust collector excl frame Length 2590 mm 1360 mm Width 2480...

Page 125: ...ng capacity min 22 5 kW Required oil tank min 350 liters Please contact Blastrac to get more details about other hydraulic requirements for the 2 45TDC machine Technical data Rated speed blower fan 29...

Page 126: ...ipment on applications where you expect dust that is classified to be harmful If you feel uncertain ask local authorities for assistance The manufacturer will not be liable for damage resulting from i...

Page 127: ...draulic power pack or PTO this power pack or PTO must be designed and operated in accordance with the directives of Blastrac in order to ensure that all devices are functioning and to eliminate possib...

Page 128: ...tions 2 5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation 2 6 Precautions applicable to some particular dangerous categories 2 7 Oi...

Page 129: ...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 instru...

Page 130: ...e Operating Instructions 2 2 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 O...

Page 131: ...ellery 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 al...

Page 132: ...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 sa...

Page 133: ...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 mac...

Page 134: ...rtaken 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 s...

Page 135: ...ured against unintended restart Always dispose the contents of the dust collector before the end of the working day Observe the waste disposal regulations Hydraulic servicing work Make sure that hydra...

Page 136: ...fety off position Before welding flame cutting or grinding remove all dust and combustible materials from the dust collector and from the area and provide adequate ventilation risk of explosion When w...

Page 137: ...in a safe condition when it cannot generate any hazard Putting the equipment in the Safety off position means Put the blast cleaning machine in the safety off position according to its operating inst...

Page 138: ...ty is responsible for compliance with the safety regulations during operation and maintenance of safety devices supplied with the dust collector as well as the provision of appropriate additional safe...

Page 139: ...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 recurrin...

Page 140: ...aning lubrication and repair works and before starting the dust collector be certain that no persons are in a dangerous area 2 11 Five golden rules 1 Disconnect all drives 2 Secure them against uninte...

Page 141: ...Operating Instructions General Contents Chapter 3 3 1 Operating instructions 3 2 Hydraulic connections 3 3 Care and maintenance 3 4 Scope of supply 3 5 Description 3 6 Control panel 3 7 Air suction s...

Page 142: ...with little knowledge of the language of the user s country appropriate instruction and training must be provided Before using the dust collector personnel must be familiar with how to operate the mac...

Page 143: ...about other hydraulic requirements for the 2 45TDC machine 3 3 Care and maintenance Special attendance and regular maintenance of the machine and its parts are imperative for functioning and safety I...

Page 144: ...on Fig 3 1 1 Compressor 6 Pressure tank with valves 2 Blower Connection to filter unit 7 Cartridge filter chamber 3 Silencer Air outlet 8 Dust hopper 4 Connection to blast machine 9 Rotating valve 5 C...

Page 145: ...the abrasive Transport of dust through the system Separation of dust from the re useable abrasive Transport of dust to the dust collector Motor output 22 kW Air throughput 90 m min 5400 m h Dust hose...

Page 146: ...eam now enters the filter chamber of the dust collector where the air is sucked through the filters Dust and fine particles are separated from the air by the filters With every pulse of the pulse syst...

Page 147: ...2 45TDC Operating Instructions Transport Contents Chapter 4 4 1 General notes 4 2 Transport 4 3 Operation 4 4 Unit specifications 1...

Page 148: ...transported The dust collector can not be lifted from the truck floor The maximum load weight of the dust collector is shown in Chapter 1 Technical data Because of traffic safety local and general sa...

Page 149: ...2 45TDC Operating Instructions Initial operation 1 Contents Chapter 5 5 1 Preparations for initial operation 5 2 Initial operation...

Page 150: ...carried out by qualified specialists Regular inspection is important in order to avoid downtimes of your dust collector Carry out the following checks before any start up Check whether all dust collec...

Page 151: ...ices Check that the dust hoppers of the dust collector are empty First switch on the rotating valves to fill the big bags 5 2 Initial operation All persons in the proximity of the dust collector must...

Page 152: ...tion 1 Contents Chapter 6 6 1 Operation 6 2 Hydraulic system 6 3 Emptying the dust hoppers 6 4 Switching off the machine 6 5 Troubleshooting 6 6 Safety shutdown 6 7 Restarting after a fault 6 8 Measur...

Page 153: ...complete manual describing all controls and settings 6 3 Emptying the dust hoppers The level of the dust hoppers must always be checked Make sure the hoppers are empty before transportation Safety pr...

Page 154: ...nformation the local safety regulations are valid in any case for the operation of the dust collector First put the truck dust collector to its Safety off position Afterwards start searching for the f...

Page 155: ...l period Make sure that the dust hoppers of the dust collector are empty Protect the electric and hydraulic components from moisture heat dust and shocks Clean the dust collector and the blower Preser...

Page 156: ...ter 7 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 Belts 7 5 Fitting the belts 7 6 Tensioning the belts 7 7 Taper locks 7 8 Replacing the filter cartridges 7 9 Air pulse s...

Page 157: ...e indicated number of working hours is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a year Due to different working...

Page 158: ...ediments of dirt or foreign bodies Remove foreign bodies and dust deposits Check the hydraulic connections for sediments of dirt or foreign bodies Remove foreign bodies and dust deposits Check the hyd...

Page 159: ...haft seals of the rotating valves for release of dust Replace if necessary Every month Check the bearings of the rotating valves for more higher noices Replace if necessary Check the motor reductors o...

Page 160: ...nce or which are required to replace wear parts If you replace parts yourself for specific reasons the following instructions and work sequence have to be observed You should also stock all spare or w...

Page 161: ...from rust grease dirt and damages The use of belt wax or similar substances to increase the friction coefficient is unnecessary and damages the belts Avoid any contaminations by oil grease or chemica...

Page 162: ...er locks are used to shrink fit hubs on shafts Mounting and demounting only requires a screw driver DIN 911 Allan key Tightening and loosening is effected with the same threaded pins or screws Taper l...

Page 163: ...ock into the pulley Lubricate the screws slightly and insert them into the respecting threaded holes Clean the shaft and shift the pulley with the taper lock as one unit onto the shaft and position th...

Page 164: ...t hoppers 2 This has to be done very carefully Swing down the dust hoppers only when the driving motors are in standstill and the main switch of the machine is secured Unscrew most of the nuts holding...

Page 165: ...sher end up in your hands or pockets Spares are available at Blastrac Remove the old filter cartridge and replace it with a new one While mounting a new filter cartridge make sure that its rubber gask...

Page 166: ...of pressurized air built up by a belt driven compressor The air is led through a water separator to the pulse system 1 Compressor 2 Water separator Fig 7 7 The conditioned air then passes a control va...

Page 167: ...7 11 If inspection of the water separator or compressor shows no dirt it is possible that either there is a leakage in the air tubing or the control valve is defect In that case replace the defective...

Page 168: ...he oil level must be approximately halfway of the oil level indicator indicating about 0 25 liter Use only oil especially made for compressors according to the specification C T 68 ISO 68 viscosity Pr...

Page 169: ...2 45TDC Operating Instructions Electrical hydraulic systems Contents Chapter 8 8 1 Circuit diagram 8 2 Hydraulic diagram...

Page 170: ...cal hydraulic systems 8 1 Circuit diagram Please contact Blastrac for a complete manual containing the circuit diagram of the electrical system Contact Blastrac to get more details about the electrica...

Page 171: ...al hydraulic systems 8 2 Hydraulic diagram Please contact Blastrac for a complete manual containing the hydraulic diagram of the hydraulic system Contact Blastrac to get more details about the hydraul...

Page 172: ...2 45TDC Operating Instructions Fault diagnosis 1 Contents Chapter 9 9 1 Fault diagnosis dust collector 9 2 Fault diagnosis hydraulic and electrical system...

Page 173: ...ssor V belt Fill the leaks or replace the damaged components Tension the V belt No suction power Dirty filter cartridge Foreign air through leaks in the dust container or in the housing cover seal Air...

Page 174: ...al system Prior to any repair works on the equipment or its drives the equipment must be secured against unintentional switching on Put the machine to its Safety off position Please contact Blastrac f...

Page 175: ...2 45TDC Operating Instructions Spare parts 1 Contents Chapter 10 10 1 Compressor unit 10 2 Filter top section 10 3 Filter cartridge 10 4 Air pulse system 10 5 Filter bottom section 10 6 Blower...

Page 176: ...unit Fig 10 1 Item Part no Description QTY 1 490693 Compressor 1 2 001244 Air filter 1 3 E00635 Water separator 1 4 E00636 Bracket for water separator 1 5 491825 V belt 1 6 491824 V pulley 1 7 E01627...

Page 177: ...Suction connector 2 3 RB20504 Suction hood 1 4 E01842 Pressure sensor 1 5 490691 Control valve 1 6 001134 Air valve 6 7 2381 365 Filter vacuum gauge 2 8 RB2055 Pressure tank 1 9 E01303 Safety valve 1...

Page 178: ...Spare parts 4 10 3 Filter cartridge Fig 10 3 Item Part no Description QTY 1 001403 Venturi 24 2 739205 Cartridge hook 24 3 490803 1 Cartridge filter 24 4 B21163 Rod seal delivered with filter cartrid...

Page 179: ...cl 1 8 mbsp 6 7 E00669 Adaptor 6 x 1 8 mbsp straight 5 8 E00668 Feed through nipple 1 8 2 9 2381 365 Filter vacuum gauge 2 10 490691 Control valve 1 11 E01303 Safety valve 1 12 E01842 Pressure sensor...

Page 180: ...t hopper LH 1 6 E01872 Rotating valve incl motor bracket 2 7 E01811 Vibrator motor 2 8 E02370 Safety flange 2 9 E02376 Sensor bracket 2 10 E02367 Sensor adjuster 2 11 E14004 Level sensor 2 12 E00671 L...

Page 181: ...1 RB266 Silencer 1 2 RB2703 Blower throttle 1 3 970385 Handle 1 4 E01846 Bearing unit complete 1 5 RB270A 9 Vibration damper 1 6 RB267 Silencer adapter 1 7 E02069 Belt cover 1 8 RB270A 11 Taper lock 1...

Page 182: ...noted on shipping receipt Hand Tool Products Blastrac warrants its BLASTRAC Hand Tool Products including hand grinders and accessories against defects in material and workmanship under normal and prop...

Page 183: ...otors batteries tires and all other parts See component manufacture warranty 7 Blastrac reserves the right to make product changes or improvements without prior notice and without undertaking any obli...

Page 184: ...Warranty Registration IMPORTANT To ensure that your Blastrac machine is covered under warranty please provide the information recorded here by registering online at blastrac com or complete this page...

Page 185: ...Contact Blastrac Canada 5125 Timberlea Blvd Mississauga Ontario Canada L4W 2S3 Tel 1 866 669 6643 Fax 866 669 6644 www blastrac ca...

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