Blastrac 2-45DTM Operating Instructions Manual Download

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Original instructions

OPERATING INSTRUCTIONS 2-45DTM

VERSION 3.4

2-45D-UNIT-ROEHSLER

Summary of Contents for 2-45DTM

Page 1: ...Original instructions OPERATING INSTRUCTIONS 2 45DTM VERSION 3 4 2 45D UNIT ROEHSLER ...

Page 2: ...esundheits und Sicherheits Anforderungen der europäischen Richtlinie der Maschinensicherheit konform ist Im Falle von Änderungen an der Maschine ohne unsere schriftliche Genehmigung verliert diese Erklärung ihre Gültigkeit Modell BLASTRAC 2 45D Seriennummer 1 erfüllt die in der Maschinenrichtlinie 2006 42 EG sowie in der Niederspannungsrichtlinie 2006 95 EG wie zuletzt geändert und der EMV Richtli...

Page 3: ...ration of the dust collector 30 5 7 Procedure for replacing a filled Big Bag 30 5 8 How to replace a full BigBag 31 5 9 Blower throttle 32 5 10 Tips for working with the 2 45TDC 32 5 11 Interrupting work 32 5 12 Stopping 32 5 13 Transport 33 5 14 Touch screen 33 6 Maintenance 35 6 1 Changing the liners 37 6 2 Changing blastwheel blades impellers cages 38 6 3 Deflector maintenance 39 6 4 Side shift...

Page 4: ...ns including children with reduced physical sensory or mental capabilities or lack of experience and knowledge Blastrac BV offers a course on the use of the machine in order to make the operating and maintenance personnel familiar with all elements of the machine 2 Machine description 2 1 Blast unit The Blastrac blast cleaning machine 2 45D is a downward blasting machine with a closed abrasive cir...

Page 5: ...ive storage hopper 7 Two wire meshes are fitted to prevent any coarse contaminants from getting into the blast wheel In order to clean the wire mesh drawers the drawers can be removed from the sides 8 1 Separator cover 2 Magnetic drum 3 Deflector 4 Separator 5 Magnetic drum motor 6 Belt cover 7 Hopper part of separator 8 Separator tray 9 Hose connector 1 Separator inc hopper 2 Separator tray 3 Mag...

Page 6: ... the control cage which once it is carefully set regulates the throwing angle of the abrasive 2 4 Abrasive sealing Magnetic seals are fitted to the front and the sides of the blast housing outlet and are surrounded by rubber and brush seals At the rear there are four skid seals sliding over the floor The seals are employed to seal the blasting area in a way to avoid leakage of any abrasive The cor...

Page 7: ...pter is designed to mount a Blastrac 2 45D blast cleaning machine on a truck During blasting it is possible to shift the blast head from the total left side to the total right side outside the reach of the wheels of the truck This enables blasting as close to the sides as possible The side shift should only be used when the machine is moving forward or backwards or when the blasthead is lifted off...

Page 8: ...ust extractor This high performance machine is exclusively designed and built to be used in combination with the Blastrac 2 45D blast cleaning machine It is equipped with 24 pieces of specially designed high quality Blastrac cartridge filters The rotating valves transport all generated debris directly into 2 BigBags for easy removal The Blastrac dust extractor 2 45TDC can only be used for dry clea...

Page 9: ...provision and wearing of personal protection equipment as well as compliance with traffic regulations Dust emissions into the environment Class Value of performance L Retains at least 99 of Most Penetrating Particle Size MPPS 0 3 µm M Retains at least 99 9 of Most Penetrating Particle Size MPPS 0 3 µm H Retains at least 99 995 of Most Penetrating Particle Size MPPS 0 3 µm 1 Compressor 6 Pressure t...

Page 10: ... filter surface and end up in the dust hoppers below the filters where it travels through the rotating valves to be stored in big bags The electrobox controls all electronic components the main switch should be turned off every time after the job is done The diagrams of the electrical system are placed inside the control panel The touch screen and the electrobox both have to be turned on for eithe...

Page 11: ... safety Red reflector sticker on the rear for extra safety 3 wheel caster system to be able to drive forward and backward without the possibility of kinking the sweeper towards the rear of truck Adjustable capturing height of 20 40mm from the surface Step less adjustability behind the truck to match every position of the blast head in front Easy to operate and fast to mount Storage Folded up in th...

Page 12: ...tanders away while operating the machine They are likely not to foresee the potential dangers of the machine Distractions could cause you to lose control of the machine h Secure the work area around the machine in public areas providing an adequate safety distance from the machine Use a red and white safety chain and danger sign to enclose the work area i Persons who are not operating the machine ...

Page 13: ...ng functions must work correct test them regularly b No loose bolts and nuts are permitted c Never operate machine without the guards and or safety devices in place d Never change anything on the safety devices on the machine e The machine specially the handle grips and operator platform must be free of fats oils and has to be dry f Do not open or remove protective guards while driving gears are r...

Page 14: ...Let the pulse cleaning cycle run for 5 minutes Switch off the compressor and Main switch Remove water from the pressure tank q Always close off the inlet of the dust collector when running the pulse cleaning cycle Failure to do so results in blown out dust which can be hazardous to the health r Do not switch off or remove the exhaust and ventilation devices when the machine is running s If dust le...

Page 15: ...to stock all spare parts or wear parts that cannot be supplied quickly As a rule production standstill periods are more expensive than the cost for the corresponding spare part 3 8 Hydraulic safety a Make sure all hydraulic hose connections are tightened and there is no leakage of oil b Over tightening could damage O rings If a leak still persists remove fitting and replace O ring c Make sure the ...

Page 16: ...rly before transport h Keep the machine clean dry and humid free Protect the motors and electrical components from moisture heat dust and shocks i Always dispose the contents of the dust collector before the end of the working day Observe the local waste disposal regulations j The dust collector cannot be lifted from the truck floor k The weight of 2 45D blast unit is 1650 kg the weight of the sid...

Page 17: ...17 Manual transport mode Hoisting transport mode max 1 g or 13 8 kN Max 1 5 g or 20 7 kN Max 0 67 g or 9 2 kN ...

Page 18: ...working on this equipment Warning Hot surface Forbidden to lift persons Danger of crushing Fire extinguisher A B C powder Wear a dust mask class FFP2 or higher Ear protection is obliged Safety glasses with lateral protection are obliged CE mark on this machine Wear protecting gloves Safety shoes obliged Consult the manual before operating the machine ...

Page 19: ...nd shortens the life time of the filter cartridges Check all air hoses for leakage Blast unit Check the following parts for damage and wear blast wheels feed spouts and liners Wear will take place in form of grooves along the blade surface outwards Wear grooves are acceptable until 75 of the blade thickness has been worn away When this point is reached replace all blades as a set Check the parts o...

Page 20: ...uck is being used in conventional drive as well as in hydrostatic drive the PLC touch screen must ALWAYS be switched on There are extra safety devices that provide the hydrostatic drive to be manipulated As well as warning signs that can pop up 4 Choose your language and the main screen will open 1 2 3 4 5 6 7 8 9 10 11 1 Electrobox 2 Filter unit 3 BigBag 4 2 45 Blasthead 5 Touch screen 6 Gear lev...

Page 21: ...ears The truck will switch from its normal drive mode to hydro mode which means that the hydraulic motor will take over all functions NEVER try to shift gears when switching from Drive to Hydro NEVER try to use the reverse gear during switching This will cause irreversible damage to the hydraulic motor 7 Hydro and Hydro drive MUST both be green if not push Switch to Drive and try again 5 6 7 IMPOR...

Page 22: ...few attempts before the hydraulic mode is properly engaged 10 Renault 10 Renault First push this button on the dashboard Then push the R button The truck will go to approximately 1500 RPM This builds up the correct pressure for blasting 1 2 8 8 Put the gearbox in 8th gear high When the hydraulic mode is engaged the gearbox must be shifted to 8th gear high make sure the toggle switch is turned upwa...

Page 23: ...Connect the 4 hydraulic hoses and the electrical connector Make sure the hydraulic connectors are clean and undamaged Use brake cleaner spray to clean them if necessary The electrical connector must be dry clean and undamaged Do not proceed if there is any doubt on the condition of these parts Faulty machinery could potentially be very dangerous 11 12 12 When the blast head is connected with the h...

Page 24: ...ER touch the clutch brake or gas pedal while in hydrostatic mode 14 Release the transportation wheels from the side shift unit by moving the blasthead up off the ground They are secured with fast locking pins While the blasthead is still off the ground remove the steering handle and flip the front wheel castor up and lock it with the fast locking pin By turning on the FREEFLOW the machine will slo...

Page 25: ...pty and connected properly Put a pallet underneath the BigBags Check the Air Pressure and Pressure Diff gauges on the touch screen See chapter TROUBLESHOOTING if the gauges are in red A B Emergency shutdown Left Right Rotating valve ON OFF switches Start button for vibration motors Fasten the dust hoses on the blasthead and inside the truck to the dust extractor Use hose clamps to ensure a reliabl...

Page 26: ...e Fan Compressor unit by touching ON in the Fan Compr Section the Compressor will start automatically D Start up Blast motor 1 by touching ON in the Blast motor 1 section E Start up Blast motor 2 by touching ON in the Blast motor 2 section F Move the joystick out of the neutral position slowly forward and drive hydrostatically close to the point where blasting should start Press the cruise control...

Page 27: ...particular section NEVER touch the clutch brake or gas pedal to stop the machine while in hydrostatic mode 5 3 Switching off the machine Close the shot valves Put the joystick in neutral position Switch off the blast wheel motors Switch off the magnetic drum motor After several minutes switch off the fan Reduce the RPM s to stationary Switch off the hydraulic system Switch off the electrical syste...

Page 28: ... removing the feed spout 1 loosening the cage clamps 2 and turning of the control cage 3 1 Feed spout and shot valve 2 Cage clamp 3 Control cage 4 Turning direction of the blast wheels 1 Control cage 2 Impeller 3 Blades set of 6 4 Blast wheel The control cage 1 has a lateral window The position of the window determines where the abrasive is fed onto the blast wheel blades 3 and where it hits the s...

Page 29: ...aterally inversed way at 3 00 of a dial Move the blast head onto a 5 8 mm thick steel plate and blast for 45 seconds at full power without moving the machine from the spot Stop the abrasive flow and move the machine until the blasted area is accessible With both hands carefully feel the temperature of the blasted area The hot spot will be where the machine has developed the highest blast cleaning ...

Page 30: ... dust collector The 2 45TDC dust extractor is designed and built to work continuously all day long The 2 rotating valves make it possible to keep on blasting while one of the BigBags is being changed During the following actions it is obligated to wear a dust mask of at least class FFP3 5 7 Procedure for replacing a filled Big Bag When one of the BigBags is full a message in red will pop up in the...

Page 31: ...BigBag D Lift the pallet where the BigBag is placed on and park it in the rear of the truck floor E Place a new BigBag on a new pallet sleeve the funnel on lock it with the clamp and switch on the rotating valve again with the green switch NOTES If the BigBag is sucked against the dust outlet the Release valve can be used to reduce the suction The vibration motors can be used when the dust is not ...

Page 32: ...dges 5 11 Interrupting work This machine is built to work with continuously leave the 2 45TDC running during short interruptions When temporarily interrupting the work 1 2 hour 1 hour turn off the fan unit only Pulse cleaning of the filter system will continue and will increase the life time of the filter cartridges During a longer stand still of the dust collector first switch off the fan unit Le...

Page 33: ...of the dust collector must be emptied after each use and before transport 5 14 Touch screen DUST COLLECTOR The touch screen indicates a number of values about the dust collector which are important for the operator See the chapter TROUBLESHOOTING for more info Air Pressure This indicates the air pressure in the tank of the pulse cleaning system Pressure Diff This indicates the pressure difference ...

Page 34: ...static drive on with the gearbox in gear and let the oil cooler cool back until the temperature is returned below 50 Celsius An oil temperature indicator is placed on the hydraulic tank Oil filter Status of the oil filters filters are OK when indicator is green Filters need to be replaced immediately when the indicator turns red and shows Oil filter alarm Oil Level Status of the oil level in the o...

Page 35: ...nnections and motors for sediments of dirt foreign bodies and other contaminants Check the belt tension of the compressor and blower Check the blast wheels blades impellers control cages feed spouts liners and fasteners for damages and wear Check the magnetic rubber and brush seals for wear Check the separator parts for wear and defects Check and empty the separator trays Check the sideshift and i...

Page 36: ...ecute the first repair works on the dust collector having support of Blastrac personnel With this your maintenance personnel gets the opportunity to be trained intensely Screws bolts etc that have been removed must be replaced with those of the same quality strength material and design Pay attention to unusual noises or strong vibrations Check for the cause of every big change Call a technician if...

Page 37: ...astrac BV 6 1 Changing the liners Unscrew the top liner covers 1 and remove the top liner covers and rubber seal 2 Remove the bolt 3 in the middle of the blast housing between de cage plates Loosen the four fixing blocks 4 at the side of the blast housing holding the top outer liners and the side liners Remove the top liners 5 Loosen the nuts of the blast wheel cover 6 and pull it aside out the ma...

Page 38: ...wheel thoroughly to make sure that the new blades and impeller will fit well and to avoid any imbalance of the blast wheel Use a new central fixing bolt when mounting a new blast wheel Replace the blades with six new ones and re assemble the machine in reverse order Note blast wheel blades must be replaced as a set Replacing only some of the blades can cause imbalance of the blast wheel After each...

Page 39: ...orms a hard crust that stops the shot from moving through If this crusted dirt is not removed regularly the performance of the machine will reduce drastically The deflector should be checked and if necessary cleaned every 2 days Remove the 6 bolts that hold the deflector and lift it out of the machine Remove all of the dirt out the deflector Check the rest of the separator for dirt and sediments A...

Page 40: ...rocket profile of the side shift and the pinion that runs over it must be cleaned regularly Check the Service manual for the parts that must be replaced every one or two years or every 150 or 300 hours whatever comes first 1 Connection plate 2 Hydraulic cylinder 3 Adapter plate arm 4 Swivel bracket RH 5 Swivel bracket LH 6 Hydraulic motor 1 Machine adapter compl 6 Lift cylinder bolt 2 Side shift u...

Page 41: ...Let the machine pulse for about a half an hour Turn on the vibrating motors every 10 minutes for about 3 seconds This will clean the filters from the inside When the Pressure Diff gauge keeps indicating red the filters probably need to be exchanged If the silencer blows out dust stop the machine immediately This means probably that a filter is damaged or not fitted properly inside the filter chamb...

Page 42: ...e 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 up the hoppers leaving the corner screws tightened With three men supporting one hopper unscrew the corner nuts and lower the hopper slowly until it hangs on the two swing bolts The hopper with the rotating valve mounted is very heavy Make sure the machine is...

Page 43: ...inside the filter chamber Check the filters and replace if necessary When a filter was damaged has leaked or was mounted incorrect it has to be replaced The compartment above the filters the connecting air hoses and the silencer also have to be cleaned thoroughly Continuing work with a broken leaking filter can cause serious damage to the machine and is a health hazard 6 7 Pulse system The Dust co...

Page 44: ...ter separator or the air filter of the compressor is dirty See 6 4 Compressor and 6 5 Water separator for maintenance instructions 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 parts or have it checked by Blastrac When there is pressure but the pulse ...

Page 45: ...n of the compressor When the tension is too low the belt will slip and when the tension is too high the belt may break and cause damage to the bearings When the belt can be pressed in by hand 5 10mm it has the correct tension At 10 kg pressure 6 9 Water separator The water separator filters dirt particles oil and water from the air It is recommended to replace the filter after every 1000 operating...

Page 46: ...the belt drive must be observed continuously 6 11 Fitting the belts Release the tension of the belt drive by reducing the distance between both shafts Insert the belt in the belt pulley grooves manually without forcing the belt Tension the belt by increasing the distance between the shafts of as described below Mount the pertaining protective drive equipment 6 12 Tensioning the belts The correct b...

Page 47: ...e the pulley and taper lock are fastened and in the correct position Use an Allen key to fasten if necessary The bearing units 4 of the blower have to be greased every 3 months There are 2 greasing nipples both need about 2 pumps of grease Use LGWA 2 0 4 Bearing grease Blastrac partnr E08729 1 Silencer 7 Belt cover 2 Blower throttle 8 Taper lock 3 Handle 9 HTD Pulley 4 Bearing unit complete 10 HTD...

Page 48: ...leeve 3 4 The coupling hub and sleeve are specially designed to break in the unlikely event that something has jammed the rotating valves This way there will be minimum damage to either the motor or valves 1 Hydraulic motor 11 Level sensor 2 Motor bracket 12 Level sensor nut 3 Coupling hub 13 Big bag adapter 4 Coupling sleeve 14 Latch clamp 5 Dust hopper RH 15 Clamp ring 6 Rotating valve incl moto...

Page 49: ...e the sensor has to cleaned Use a dry clean lint free cloth to carefully clean the sensor Never use water detergents or solvents These could damage the sensor 6 15 BigBag clamp The BigBags are attached to the BigBag adapter with the clamp 14 18 The clamp is fitted with a limit switch 16 This indicates if the clamp is open or closed properly as a safety measure to prevent unintentional start up wit...

Page 50: ...te control in a protected clean dry area No lubrication is required for the life of the winch The winch lever has to point in the direction of the tailgate back of the truck Please read the OEM s Operating Instructions for more information about the winch or remote control The Remote control has a reach of 60 meter 1 Function 1 2 Function 2 3 Stop button Turns the remote control and receiver off 4...

Page 51: ...sive is removed from the blast head Flip the TEST SWITCH on the electrobox Open the separator cover of the blasthead Remove the separator trays from the side Check the shot valves for dirt and signs of wear The operator in the cabin can operate the shot valves while a second person checks the valves and actuators on the blast head Shot valve 1 is on the driver s side shot valve 2 is on the passeng...

Page 52: ... Dirty airfilter Dirty too little oil in the compressor Fill the leaks or replace the damaged components Tension the V belt Clean or replace the airfilter of the compressor Change or refill the oil Bad or no filter cleaning Pressure too low Dedusting timer card or solenoid valve defective See above Replace defective parts No suction power Dirty filter cartridges Foreign air through leaks in the du...

Page 53: ... function Broken coupling between rotating valve and hydro motor Remove the BigBag and clean sensor with dry cloth Check for damage loose wires position adjustment Check and replace if necessary Too much free movement in sideshift adapter Too much slack on bearings Too much slack on bolts Replace bearing bushes immediately Replace bolts immediately Winch does not work Winch lever No power Remote c...

Page 54: ...oncrete roughening of smooth concrete or natural stone removes coatings with a thickness of 1 3 mm cleaning of steel surfaces Media nr 5 Abrasive S460 This media is used to create a coarse profile or to increase the work speed in the case of surfaces hard to treat removes sediments on concrete prior to coating removes thick paint coatings or rust from steel surfaces bridges tanks etc removes flexi...

Page 55: ...leaning output Up to 2000 M2 h Recommended abrasive Shot 460 550 Abrasive consumption 0 1 0 5 kg M2 Required drive speed 0 5 0 km h Rated speed blower fan 2950 min 1 Rated speed rotating valve 15 20 min 1 Rated speed oil cooler 1500 min 1 Dust hose connection 2x Ø150 mm Dust hose length 2 x 7 m Pressure adjusting compressor 6 7 bar Differential pressure max 30 mbar Dedusting interval 15 20 s Airfl...

Page 56: ...mm 1550 mm Height 2650 mm 2650 mm Weight 1300 kg 900 kg Blower dimensions Blower Length 1320 mm Width 930 mm Height 1680 mm Weight 335 kg Tow behind sweeper dimensions Option Tow behind sweeper folded for transport Tow behind sweeper unfolded in use Length 1560 mm 2560 mm Width 1900 mm 1900 mm Height 670 mm 520 mm Weight 470 kg 470 kg Magnet width 1300 mm 1300 mm Side shift adapter Length 1050 mm ...

Page 57: ...ion sound pressure levels in decibel dB re 20 µPa Positions around the truck are at 1 0 m distance and at a height of 1 6 m above the ground Positions in the truck body are at a height of 1 6 m above the floor Driver position is at actual ear level The total vibration value to which the hand arm system is subjected does not exceed 2 5 m s IMPORTANT NOTES The indicated values are measured on new ma...

Page 58: ...transmitted Although the sound pressure level at the operators position does not exceed 80 dB A ear protection is still strongly recommended when working with this machine Employees surrounding the machine should always use ear protection when working with this machine Old equipment contains valuable materials which are designed for re processing The machine parts must not be thrown away in the no...

Page 59: ...ngton Sheffield South Yorkshire GB S25 3QY England Tel 0044 1909 56 91 18 Fax 0044 1909 56 75 70 Info blastrac co uk Blastrac Germany Richard Byrd Straβe 15 D 50829 Köln Ossendorf Tel 0049 221 70 90 32 0 Fax 0049 221 70 90 32 22 Info blastrac de Blastrac Spain Calle Copernico 16 Nave 2 E 28820 Coslada Tel 0034 91 660 10 65 Fax 0034 91 672 72 11 Info blastrac com es Blastrac France ZI 29 Avenue des...

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