Original instructions
OPERATING INSTRUCTIONS 2-45DTM
VERSION 3.8
2-45D-UNIT-OKLAHOMA 2017
2
Original in English language.
EC DECLARATION OF CONFORMITY
in accordance with Appendix II sub A of Directive 2006/42/EC
We,
BLASTRAC B.V.
Utrechthaven 12
NL - 3433 PN NIEUWEGEIN
The Netherlands
declare under our sole responsibility that the complete blast cleaning system for roads and highways as
described below,
Model: 2-45D-UNIT-OKLAHOMA 2017 consisting of the following equipment :
BLASTRAC 2-45D-0030 Blast cleaner Serial number: 21973B
BLASTRAC 2-45TDC-0010 Dust collector Serial number: 21978B
satisfies the conditions set out in the:
Machinery Directive (2006/42/EC);
Low Voltage Directive (2014/35/EU);
EMC Directive (2014/30/EU);
Noise Emission Directive (2005/88/EC)
Where appropriate, are in conformity with the following harmonized standards:
NEN-EN-ISO 12100:2010
NEN-EN-IEC 60204-1:2006/C11:2010
In case of changes to the machine without our written authorization this declaration loses its validity.
Machines mounted on Peterbilt truck with vehicle identification number / chassis number
1BPZL70X3HF174839.
Nieuwegein 18-1-2018
Michiel Kalisvaart
Operational Manager
3
1. Introduction 4 Index
2. Machine description 4
2.1 Blast unit 4
2.2 Separator, magnetic drum and hopper 5
2.3 Blast wheel 6
2.4 Abrasive sealing 6
2.5 Side brush housing 7
2.6 Side shift and adapter 7
2.7 Dust collector 2-45TDC 8
2.8 Tow behind sweeper 11
3. Safety 12
4. Initial operation 20
4.1 Checkpoints: 20
4.2 Switching from ‘Drive-mode to ‘Hydro-mode’ 21
4.3 Tow Behind Sweeper 24
4.4 Connecting the blast unit with the truck 25
4.5 Start-up of the dust collector 27
4.6 Connecting the Tow Behind Sweeper 28
5. Operation of the blast unit 29
5.1 Before blasting 29
5.2 Blasting with the 2-45DTM 29
5.3 Switching the machine off 30
5.4 Driving backwards 30
5.5 Adjusting the blast pattern 31
5.6 Setting the control cages 32
Operation of the dust collector 33
5.7 Procedure for replacing a filled Big Bag 33
5.8 How to replace a full BigBag 34
5.9 Blower throttle 35
5.10 Tips for working with the 2-45TDC 35
5.11 Interrupting work 35
5.12 Stopping 35
5.13 Transport 36
5.14 Touch screen 36
5.15 Cleaning up after work 38
6. Maintenance 39
6.1 Changing the liners 42
6.2 Changing blastwheel blades, impellers & cages 43
6.3 Deflector maintenance 44
6.4 Side shift & adapter maintenance 45
6.5 When to change the filters? 46
6.6 Filter replacement 47
6.7 Pulse system 49
6.8 Compressor 51
6.9 Water separator 52
6.10 Belt drives, fitting and tensioning 53
6.13 Blower maintenance 54
6.14 Rotating valves 55
6.15 BigBag clamp 56
6.16 24V Winch and remote control 57
6.17 Shot valves and actuators 58
6.18 Touchscreen calibration 58
6.19 Spring loaded shot guide 59
7. Troubleshooting 60
8. Selection of abrasive 62
9. Technical data 63
9.1 Sound and vibration data 65
4
1. Introduction
Before use, operators shall be provided with information, instruction and training for the use of the machine
and the substances for which it is to be used, including the safe method of removal and disposal of the
material collected. All persons who are working with or maintaining this machine must read the manual
carefully and understand it fully. In case you sell the unit, hand the operating instructions on to the next
owner. Keep this manual always with the machine, to enable it to be referred to at any time.
Any other work not covered by this operating manual must not be carried out. Always use common sense
when working with machines.
This machine is designed for industrial use by professionals. Only authorized and trained personnel may
operate this machine. This machine is not intended for use by persons (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.
It is forbidden to drive on public roads when the blast unit + sideshift & adapter are mounted to
the front of the truck. Only when the truck is in hydro drive-mode it is allowed to drive short distances on a
slow pace with the blast unit + sideshift & adapter mounted to the front of the truck. Ignoring this command
will result in expensive damages to the machine and truck.
2. Machine description
2.1 Blast unit
The Blastrac blast cleaning machine 2-45D is a downward blasting machine with a closed abrasive circuit
exclusively designed for the pre-treatment of dry, frost-free, horizontal surfaces. The bouncing impact of
metallic abrasive onto the surface to be treated thoroughly removes surface contaminants, coats of paint,
sealants and thin coatings.
A suitable filter unit must be connected to the machine in order to separate the dust from the abrasive.
A specially designed dust collection system ensures dust-free operation of the machine and clean air at the
workspace.
2.1 Blast unit
2.6 Side shift & Adapter
2.7 Dust collector
2.8 Tow behind sweeper (Option)
5
2.2 Separator, magnetic drum and hopper
The abrasive separator is mounted to the end of the recovery duct. It separates the abrasive from
contaminants and feeds the cleaned abrasive onto the magnetic drum(2). This magnetic drum functions as a
second separator for bigger particles and feeds the cleaned abrasive back to the abrasive 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 including hopper
2
Separator tray
3
Magnet drum drive
4
Dust hose connection
5
Feed spout
6
Control cage clamps
7
Abrasive sealing
8
Rebound
9
Transport castor (foldable)
6
2.3 Blast wheel
The heart of the blast cleaning machine are two blast wheels that throw the abrasive onto the surface to be
cleaned by using centrifugal force. The blast wheels are placed in a protective housing lined with replaceable
wear parts. The blast wheels are driven by two hydraulic motors.
1 Control cage
2 Impeller
3 Blades (set of 6)
4 Blast wheel
Around the centre of the blast wheel there is the impeller feeding dosed quantities of abrasive onto the blades
of the turning blast wheel. On top of this is 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 correct height adjustment of the magnetic seals (16-20 mm) is very important for optimum functionality of
the machine. The adjustment can be carried out by means of shaft nuts at the front and rear wheels.
1 Side brush housing
2 Side magnet
3 Front magnet
4 Front brush
5 Front seal rubber
6 Side seal rubber
7 Rear brush
7
2.5 Side brush housing:
The inner- and outer side brush are able to float over the treated 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 screws mounted at the side.
1 Brush housing
2 Side brush spring
3 Guide
4 Felt seal
5 Side brush inner
6 Side brush outer
2.6 Side shift and adapter
The side shift and machine adapter 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 the
ground. Using the side shift in standstill position with the
blasthead on the ground could damage the oil pump.
Don’t use the equipment for any other purpose than to mount a
2-45D blast cleaning machine to a truck.
Please note that the illustrations are simplified.
8
There are 4 hydraulic connections, 1 electrical connection and 2 sleeve
bolts to connect the side shift & adapter to the front of the truck.
The 4 hydraulic rotary couplings should be cleaned before and after
each use. Use brake cleaner or something similar to do so. Use the red
protection caps after each use.
Place a bucket underneath the couplings when connecting or
disconnecting them to catch the drops of oil that may be spilled.
The electrical connection on the truck has a clamp to lock the connector
in place, always use this to prevent any water or dust entering the
connector during work.
The electrical connection on the truck also has a protective cap, always
close it during transport.
The sleeved bolts should always be tightened firmly. Use the wrench
and socket wrench to do so.
2.7 Dust collector 2-45TDC
The 2-45TDC is a very powerful truck mounted dust 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 cleaning.
It should only be used for removing noncombustible/non-explosive dust or substances.
The 2-45TDC may not be used for carcinogenic or pathogenic substances.
The machine is designed for usage in conditions according to classification M (see below).
Classification according to standard EN 60335-2-69 – Annexe AA
Class
Designation
L
(light hazard) suitable for separating dust with a limit
value of occupational exposure of
greater than 1 mg/m³
M
(medium hazard) for separating dust with a limit
value of occupational exposure not
less than 0,1 mg/m³
H
(high hazard) for separating all dusts with all limit
values of occupational exposure,
including carcinogenic and pathogenic dusts.
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In the case of dust harmful to health, contact the local health and safety authorities, and observe national
regulations in force both during use and disposal.
In addition to the Operating Instructions general and legal regulations regarding accident prevention and
environmental protection must be complied with and indicated!
Such duties may for example relate to the handling of hazardous substances or to the provision and wearing of
personal protection equipment as well as compliance with traffic regulations.
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 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
Connection to blower
10
BigBag adapter / Dust outlet
10
The air streaming through the complete system during the application of
the blast cleaning machine and dust extractor has the following functions:
- Cooling of the blast wheels
- Cooling of the abrasive
- Transport of the abrasive
- Transport of dust through the system
- Separation of the dust from the re-useable abrasive
- Transport of the dust to the dust collector
The dust extractor is provided with an air pulse cleaning system which increases the life of the filter cartridges.
This system works by use of pressurized air, built up by a belt driven compressor. The air is led through a
water separator to the pulse system.
The conditioned air then passes a control valve which regulates the system pressure, and then builds up
pressure in the pulse tank.
The pressurized air is used to generate a pulse of air which cleans the filters from the inside. With every pulse
of the pulse system all dust and particles are released from the 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 either of them to work.
The truck’s engine power is transmitted to the hydraulic PTO (13), to allow smooth
driving at low speeds and ensure high blasting power from the blast unit. The
hydraulic system runs at or below 250 bar.
During transport the blast unit has to be stored inside the truck. Use the safety
chains to secure it inside.
Inside the truck you will also find a toolbox mounted to the wall and a powder fire
extinguisher. This powder extinguisher is suited for: Solid materials (A), Liquids (B),
and Gasses (C). It is also safe to use on electrical components under current
(minding the collateral damage).
11
Electrobox
12
Touch screen inside the cabin
(PLC)
13
Oil tank for hydraulic system
(PTO)
14
2-45D Blast cleaning machine
11
12
13
14
11
2.8 Tow behind sweeper (option)
The Blastrac 2-45TBS is a fully hydraulic controlled automatic magnetic sweeper. It can be mounted at the
back of the truck and it will pick up the abrasive that was left behind after blast cleaning.
The magnets will pick up the abrasive from the surface and the conveyor-belt will transport it to the rear for
safe access to the storage buckets. The tow behind sweeper has 6 “easy buckets”, 5 on the sweeper, and one
spare for changing during operation.
The 2-45 tow behind sweeper is equipped with the following features:
Electrical on/off buttons.
Emergency shutdown button (stops all hydraulic devices of the truck unit).
2 rear mounted flash lights for extra safety.
Red reflector sticker on the rear for extra safety (option).
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 the rear of the truck unit to save space and time by the use of extra brackets that fit on
the tail lift.
Storage mode.
The tow behind sweeper is attached to
the tailgate with the special brackets
and a strap.
When released from the tailgate, the
sweeper can be folded out.
Slide the metal tube through the sockets
and secure it on the back of the truck.
There are 2 hydraulic couplings and 1
electrical connector, connect them with
the truck. Make sure the couplings are
undamaged and clean.
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3. General Safety Rules
Warning!
Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire, explosions and / or serious injuries.
Only authorized and trained personnel may operate this machine. This machine is not
intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack
of experience and knowledge.
It is the responsibility of the user to analyse the surface to be treated. The surface may not contain any
substances which could pose a fire-, explosion- or health risk when treated. The user should make a risk
assessment on the basis of the information obtained about the surface to be treated and take proper
precautions for the work to be performed.
In case of any inappropriate usage, improper operation or repair, the producer shall be exempt from liability.
3.1 Work area safety
a) Do not use the machine in rain, damp or wet locations.
b) Avoid dangerous environments: do not work in the presence of explosive atmospheres, in the
presence of flammable liquids, gases or dust. Remove materials or debris that may be ignited by sparks.
In some cases sparks could be created by shot/steelblasting
c) The surface to be treated must be swept, make sure to remove all stones, screws etc..
Any stones, screws, bolts, pieces of wire etc. could cause serious damage to the machine if it gets inside
the machine!
d) Make sure there is enough ambient light on the work area. Cluttered or dark areas invite accidents.
e) Only load and unload the blast head on a levelled and horizontal surface! Steep inclines could
cause a dangerous situation when you lose control over the blast head!
f) It is necessary to provide for an adequate air change rate L in the room if the exhaust air is returned to
the room. Comply with the National regulations.
g) Keep children and bystanders 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 must not be permitted to stay in the surrounding area of at
least 15 meter from the machine.
j) Make sure all persons who will be working with the machine know where the fire extinguisher is.
k) Never use the machine when the surface is not clear and if there is a risk of stumbling or tripping.
l) Make sure that there is nothing standing or situated on the surface to be treated.
m) Make sure the machine can travel over all inequalities on the surface, small inequalities like weld seams or
floor joints are no barriers for the machine.
n) Never operate the machine when workplace is wet. Never stay in the rain with the machine.
o) Remove reinforcing steel or other objects protruding from the surface in order to prevent damage to the
machine.
p) Warning! Make sure that the surface to be treated does not contain dangerous materials
such as: - combustible or explosive dusts or substances.
- carcinogenic or pathogenic substances.
q) Ensure the provision of the right safety clothing, road signs, licenses and instructions.
r) In terms of work on public roads, there should be a buffer zone created where speed in km will be
converted into meters for a buffer zone, for example: maximum speed is 100 km/h = 100 meter buffer
zone (closed road). Always mind the local safety requirements for work on roads, bridges etc.
s) It is forbidden to drive on public roads when the blast unit + sideshift & adapter are mounted
to the front of the truck. Only when the truck is in hydro drive-mode it is allowed to drive short
distances with the blast unit + sideshift & adapter mounted to the front of the truck.
3.2 Electrical safety
a) Any damage to the electric cables and/or electrical components is not permitted.
b) If a cable or plug is damaged, it must be replaced immediately. Only use original Blastrac parts.
c) Inspect and test the electrical components regularly. The electrical components have to satisfy with the
requirements set out in the harmonised norm EN60204-1.
13
d) Always call a skilled electrician or your distributor when you have questions about the safety of the
electrical components.
e) Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by
trained persons under the guidance and supervision of a skilled electrician as well as in accordance with
the electrical engineering regulations.
f) Always use tools that are insulated against voltages.
g) Keep the machine original; Use cables who are approved and not damaged.
h) The machine is always equipped with earthed connections, do not change this.
i) Be careful, electrical cables/connections must not come into contact with water.
j) The main power switch of the machine must be secured in the “Off” position before inspections, repair or
maintenance.
k) Always turn off the main power switch after the job.
3.3 Personal safety
a) Always wear Personal Protective Equipment while working with or around the machine!
-Dust mask class FFP3 or higher
-Hearing protection
-Safety glasses with lateral protection
-Protecting gloves
-Safety shoes
b) Always wear close-fitting protective clothing. Do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts.
c) Stay alert, watch what you are doing and use common sense when operating the machine.
d) Make sure the machine is turned off and all moving parts have come to a complete standstill before any
inspections, adjustments and/or maintenance work is started.
e) Always seek professional medical attention immediately in case of injury.
f) All persons surrounding the machine should wear Personal Protective Equipment.
3.4 Machine safety general
a) Safety functions and operating 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 running.
g) The machine will heat up during work, don’t risk getting burned, always wear gloves and only touch the
handle grips.
h) A second person must be deployed who can disengage the hydraulics and switch off the PTO in an
emergency if work on live parts is necessary. The work area must sealed off using a red and white safety
chain and a danger sign.
i) All repair work has to be done by qualified Blastrac personnel, this guarantees a safe and reliable
machine.
j) Always use original Blastrac spare parts, filters and abrasive, this will ensure the best performance.
Only original parts meet the factory specifications and quality. Otherwise Blastrac BV cannot guarantee
the safety of the machine. The part numbers can be found in the Service Manual.
3.5 Safety regarding the blast unit
a) Never lift the blast head during blasting!
This could cause serious injury to yourself and others around you!
b) Abrasive can escape from the sides of the blast head at high speed. Wear safety glasses with lateral
protection and close-fitting protective clothing.
c) In some cases sparks could be created by shot/steel blasting.
d) Check the following parts daily for damage and wear to avoid unnecessary long and costly standstill on
the workplace; blastwheel, feedspout, liners, magnet- and brush sealing;
Replace the parts when you can see obvious signs of wear and tear.
Wear grooves are acceptable until 75% of blade thickness has been worn away. When this point is
reached, replace all blades as a set.
e) If the length of the brushes is, due to wear, less than 5mm or they are extremely deformed, the brushes
have to be replaced. Check the Service Manual for the order numbers.
14
f) Check the parts of the separator on wear and defects. Remove foreign bodies and dust deposits to
prevent clogging of the separator.
g) The cover of the separator and separator tray must be closed to keep the vacuum in the machine.
h) The machine will heat up during blasting, don’t risk getting burned, always wear gloves and only touch
the handle grip(s) and control devices.
i) Always switch on the dust collector before blasting!
3.6 Safety regarding the dust collector
a) The Blastrac dust collector can only be used for dry cleaning.
It should only be used for removing noncombustible/non-explosive dust or substances.
b) The 2-45TDC may not be applied for carcinogenic, pathogenic or asbestos substances.
c) Do not use the machine in the presence of dangerous atmospheres like flammable gasses or dusts.
d) The machine is designed for usage in conditions according to classification M.
e) Do not point the hose at people or animals.
f) Never use this machine for sucking up water or liquids.
g) Acids, acetone or solvents can damage the machine.
h) Never use the machine without the filters in place!
i) Make sure that the rotating valves are in good working condition.
j) Never use the machine without big bags attached.
k) Regularly check the contents of the BigBags. Always wear a dust mask of at least class FFP3 when
changing the BigBags. Comply with the local waste treatment regulations considering the removed
material.
l) The dust hoses must be connected properly with a hose clamp and industrial tape.
m) The dust hoses must be undamaged and free of obstructions.
n) Regularly use the air pistol and release valve to remove water from the air tank.
o) 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.
p) During a longer stand still of the dust collector, first switch off the fan unit. 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 leaves the filter unit instead of clean air, this is a sign that the filter cartridges are damaged or not
fixed correctly inside the chamber. Do not proceed! Rectify immediately!
t) When a filter is leaking it has to be replaced. The compartment above the filters and silencer also have to
be cleaned thoroughly.
u) Compartments that are not dust-tight must be opened with suitable tools and thoroughly cleaned.
v) Operators should observe all safety regulations appropriate to the materials being handled.
w) NEVER expose the filter cartridges to moisture!
3.7 Maintenance safety
a) Disconnect the blast unit completely from the trucks electrical and hydraulic system before starting
inspections and repair work on the machine. The main switch can be locked in the “OFF” position by using
a padlock and placing it through the main switch. Turn the contact key to OFF and press Emergency
shutdown.
b) Wait for a standstill of all drives before any inspections, adjustments and/or maintenance work is started.
Disengage the hydraulics / switch the PTO (Hydraulic unit) off.
c) Use the air pistol to depressurize the air pressure tank before maintenance.
d) Block machine in stable position before doing any maintenance work.
e) To allow the user to carry out maintenance operations, the dust collector must be disassembled, cleaned
and inspected as far as reasonably possible, without causing hazards for the maintenance staff or other
people.
f) The suitable precautions include decontamination before disassembling the dust collector, adequate
filtered ventilation of the exhaust air from the room in which it is disassembled, cleaning of the
maintenance area and suitable personal protection equipment.
g) The external parts of the dust collector must be decontaminated by cleaning and vacuuming methods, de-
dusted before being taken out from the hazardous zone. All parts of the dust collector must be considered
as contaminated when they are removed from the hazardous zone and appropriate actions must be taken
to prevent dust from dispersing.
h) When maintenance or repair procedures are carried out, all the contaminated elements that cannot be
properly cleaned, must be destroyed.
15
i) These elements must be disposed of in sealed bags according to the applicable regulations and in
accordance with the local laws governing the disposal of such material.
j) This procedure must also be followed when the filters have to be disposed.
k) If dust leaves the filter unit instead of clean air, this is a sign that the filter cartridges are damaged or not
fixed correctly inside the chamber.
l) When a filter is leaking it has to be replaced. The compartment above the filters and silencer also have to
be cleaned thoroughly.
m) Compartments that are not dust-tight must be opened with suitable tools and thoroughly cleaned.
n) A second person must be deployed who can disengage the hydraulics and switch off the PTO (Hydraulic
unit) in an emergency if work on live parts is necessary. The work area must be sealed off using a red and
white safety chain and a danger sign. For the electrical parts, use a tool that is insulated against voltages.
o) WARNING! Do not weld, flame cut or perform grinding works on or near the dust collector.
Danger of fire or explosion exists!
p) Provide adequate ventilation when working in a confided space.
q) Secure the maintenance area if necessary.
r) Failures due to inadequate or incorrect maintenance may generate very high repair costs and long
standstill periods of the machine. Regular maintenance therefore is imperative.
s) Operational safety and service life of the machine depends, among other things, on proper maintenance.
t) Prevent premature wear by keeping the machine as dust free as possible. Clean the machine for this
reason regularly with a dust collector and non-aggressive materials, never use a high pressure water
cleaner to clean the machine.
u) Do not use any aggressive cleaning materials! Use lint-free cleaning cloths!
v) The Gearbox settings menu indicates the time left before the gearbox should be serviced.
w) It is advisable 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 hydraulic hoses have no damages, signs of wear and tear or other defects.
d) Hydraulic fluid under pressure is dangerous and can cause serious injury.
e) Hoses and pipe work can be under high hydraulic pressure. The temperature can be above 37° C. Use
only hoses and pipe work that are sized and marked in accordance with the overall power consumption of
the machine.
f) The system runs at or below 250 bar. Never look for a leak when the unit is under pressure.
g) Avoid leaks by keeping fittings and hoses tight, only check and service when not under pressure.
h) Leaking hydraulic fluid is not only unsightly, it’s dangerous. It could make workplace floors slippery,
contaminate the environment and could create a possible fire/explosion hazard.
i) Never change the oil pressure of the machine! Changing the oil pressure could cause serious damage to
the machine and could result in very dangerous situations!
j) Only work with the hydraulic oil in an area that is well-ventilated, otherwise you must wear suitable
respiratory protection. Always wear Personal Protective Equipment when handling the oil:
-Protecting gloves (preferably made of nitrile or neoprene.)
-Safety goggles.
-Hydrocarbon-proof clothing and safety shoes.
k) Avoid long and repeated contact with the skin, after contact wash thoroughly with water and soap.
Contact with eyes: Immediately flush eyes with cold, fresh water for a minimum of 15 minutes. Seek
professional medical attention.
l) Do not eat, drink or smoke near the hydraulic oil.
m) HV46 hydraulic oil holds no danger of intoxication.
n) The hydraulic oil is stable at normal temperatures for storage, handling and use. However, the hydraulic
oil is flammable when exposed to certain conditions. Empty containers may contain flammable or
explosive vapors. Rags that are soaked with the product and paper or materials which have been used for
absorbing the spilled product are inflammable. Make sure that no accumulation occurs. Remove safely
after use.
o) Avoid sparks, open flames, extremely high temperatures and other sources of ignition.
p) Please read the Safety Data Sheets for additional information regarding the hydraulic oil.
q) Only use HV46 hydraulic oil (E00481), non-compatible fluids could cause damage to the unit or serious
injury.
r) Level should be half the glass of the level indicator. If you don’t see the oil in the indicator, the level is too
low. If the level is above the glass, the level is too high.
16
s) At least once a year the oil from the system and the oil filter should be replaced.
t) Work on hydraulic equipment or operating materials may only be undertaken by a skilled hydraulic
engineer or by trained persons under the guidance and supervision of a skilled hydraulic engineer as well
as in accordance with the hydraulic engineering regulations.
3.9 Transport safety
a) Be aware of your surroundings and machine operating level. Do not side hill, do not run on steep incline,
this could cause machine to tip over.
b) Only load and unload the blast head on a levelled and horizontal surface! Steep inclines could
cause a dangerous situation when you lose control over the blast head!
c) Always obey the local traffic safety regulations when working with this machine.
d) Remove the abrasive from the abrasive storage hopper before transport or storage.
e) Remove the dust from the dust collector before the dust collector is transported.
f) For class H and M machines, the outside of the machine should be decontaminated by vacuum cleaning
methods and wiped clean or treated with sealant before being taken out of a hazardous area. All the
machine parts shall be regarded as contaminated when removed from the hazardous area and appropriate
action taken to prevent dust dispersal, take precautions to prevent dust from escaping.
g) Make sure the dust hoses are disconnected and put away properly 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 side shift & adapter is 1000 kg. Use a crane
or lift when transporting the machine, use the lifting eyes / lugs of the machine.
l) Before every use check the lifting eyes/lugs and welds for:
deformation, damages, cracks, corrosion and wear.
m) Each lifting lug has a WLL of 1500kg, only lift the machine as shown in the picture below.
n) When lifting the machine from the ground, always use the lowest lifting speed. The cables must first be
tensioned at this speed; they must not be slack when the machine is lifted from the ground.
o) During hoisting make sure to be at a safe distance from the machine with the most optimal view on the
machine and working environment.
p) Never stand directly below the machine.
q) When transporting the machine do so in such a manner that damage due to the effects of the use of force
or incorrect loading and unloading is avoided.
r) The lifting eyes/lugs can also be used to fasten the machine on a pallet or during transport.
s) Chock wheels for transport and keep control handle in neutral position.
t) Don’t leave the machine unsecured on jobsites.
u) Always park the machine on a flat horizontal and levelled surface.
v) Make sure the electrical cable and hydraulic hoses are disconnected between the blast unit and truck.
w) Store the cleaned and dry machine in a humid free room. Protect the machine from moisture, heat dust
and shocks.
x) Never use the machine for lifting persons or items.
y) Because of the traffic safety, the truck blast unit, the side shift & adapter and tow behind sweeper must
be stored inside the truck before it is transported. Local and general safety precautions and accident
prevention guidelines are to be followed.
z) It is forbidden to drive on public roads when the blast unit + sideshift & adapter are mounted
to the front of the truck. Only when the truck is in hydro drive-mode it is allowed to drive short
distances with the blast unit + sideshift & adapter mounted to the front of the truck.
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
18
3.10 Signs on the machine
The following stickers are placed on the machine. Meanings of these symbols are:
! Danger Hazardous voltage in motor
even when solid state controller is OFF.
Disconnect main power before servicing
motor, controller or associated wiring.
Forbidden to lift persons.
Lifting point.
Wear a dust mask class FFP3 or
higher.
Hearing 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.
No lifting point.
DANGER Rotating parts inside.
Keep hands clear.
Lock-out / shut down before servicing.
Warning! Hot surface.
No unauthorised person may operate
this machine.
Fire extinguisher (A B C powder).
Drain airtank daily.
Open drain valve to remove water from
air tank daily.
Hearing protection and safety glasses
are obliged.
Keep a distance of 20 cm from the
magnet with active or passive medical
devices.
The A-weighted sound power
level of 102dB.
A-weighted emission sound
pressure level of 96dB.
Name, address and website.
The machine type.
The net weight of the machine in kilogram.
The year of manufacture.
The serial number of the machine.
Email, website, telephone number, fax number.
19
3.11 Safety regarding magnets
The 2-45D blasthead and 2-45 TBS tow behind sweeper contain static magnets, none of them exceed the
Exposure Limit Values (0-1 Hz) of the DIRECTIVE 2013/35/EU on the minimum health and safety requirements
regarding the exposure of workers to the risks arising from electromagnetic fields. However, the Action levels
(ALs) for magnetic flux density of static magnetic fields could form a risk for workers at particular risk such as:
Workers wearing active implanted medical devices (AIMD)
Workers wearing passive implanted medical devices containing metal
Workers wearing body-worn medical devices
Pregnant workers
Static magnetic field Action Levels (AL)
An AL of 0.5 mT is specified to limit interference with the function of active implanted medical devices. The EMF
Directive also provides an AL of 3 mT to limit the projectile risk in the fringe field from strong sources (> 100 mT).
Workers with active or passive medical devices should be
careful around the Tow Behind Sweeper. The areas that
could pose a risk are indicated with warning signs. Keeping a
distance of 20 cm from the magnet of the Tow Behind
Sweeper will ensure the safety of workers with active or
passive medical devices.
During normal activities there should be little to no risk from
the magnet inside the 2-45D blasthead because of the design
and the way the magnets are encapsulated and shielded.
However, take caution when performing maintenance,
cleaning and / or repair because then the magnets could be
less shielded and thus forming a possible risk for workers
with active or passive medical devices.
Keeping a distance of 20 cm from the magnet
will ensure the safety of workers with active or
passive medical devices.
View of the magnetic separator
inside the 2-45D blasthead
Sideview of the Tow Behind Sweeper
Front view Tow Behind Sweeper
20
4. Initial operation
Before using the machine it is of great importance to inspect the machine.
It is not permitted to use the machine if the machine safety is not according the checkpoints below.
4.1 Checkpoints:
Machine in general
Operating and safety functions must work correct.
Check all screws and other fasteners for tightness. No loose bolts and/or nuts are permitted.
Check the electrical components, cables and connections for wear and/or damages.
Check all hydraulic components, connections and hoses for oil leakage, wear and/or damages.
Dust collector
Dust hoses must be undamaged and free of obstructions. The connections must be reliable: use hose
clamps and industrial tape.
Make sure that the Big Bags are empty and connected properly. Put a pallet underneath the BigBags.
The filter housing must be sealed in properly and all seals must be in good condition.
If dust leaves the filter unit instead of clean air, this is a sign that the filter cartridges are damaged or
not fixed correctly inside the chamber.
All water must be removed from the air tank and drain box. Excessive water can have a negative
impact on the pulse power and 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 of the separator on wear and defects. Remove foreign bodies and dust deposits.
Check the level of abrasive in the storage hopper. Refill if necessary.
Check the front, side and rear magnet and brush seals for wear.
Work area
Check the surface to be treated for loose parts (stones, screws, etc.) The surface must be swept if
necessary. Make sure the machine can travel over all inequalities on the surface. Small inequalities like
weld seams or floor joints are no barriers for the machine
Secure the work area around the machine providing an adequate safety distance from the machine.
Use a red and white safety chain and danger sign to enclose the work area.
Remove reinforcing steel or other objects protruding from the surface in order to prevent damage to
the machine.
Warning! Make sure that the surface to be treated does not contain dangerous materials
such as: - combustible or explosive dusts or substances.
- carcinogenic or pathogenic substances.
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