Blastrac 2-4800DH Owner's manual

MODEL

2-4800DHMKII

OPERATING INSTRUCTIONS

SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL

OPERATORS OF THIS MACHINE!

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Revision May 2004

INTRODUCTION

This manual has been prepared to assist the operator and maintenance

personnel in understanding the machine so that it may be operated in the safest

and most efficient manner and maintained in the best condition. Therefore, it is

necessary that all personnel responsible for the operation and maintenance of

the machine read and understand the manual.

Before attempting to operate service or maintain the machine, the personnel

should thoroughly familiarize themselves with the physical make-up of the

machine. They should be familiar with the major components of the machine and

have a general understanding of overall operations.

The operating and maintenance personnel must obey all the warnings and safety

precautions posted on the machine and stated throughout this manual. Serious

injury to personnel or severe damage to the equipment may result if the warnings

and precautions are not followed.

You will be notified of any changes that occur after this manual is printed. We

will send you manual revisions that should be inserted in the manual in

accordance with instructions that will be forwarded with them.

Receipt of Machine

Examine the shipment carefully for possible damage that might have occurred

while in transit. If any damage is noted, notify the transportation carrier

immediately and advise Blastrac.

FORWARD

Blastrac is pleased that you have selected this Blast Cleaning System for your

surface preparation requirements. This closed-cycle, dust reducing, surface

preparation machine has been designed and built for abrasive blast cleaning of

horizontal surfaces.

This manual has been prepared to assist the operator and the maintenance

personnel in understanding the machine so that it may be operated in the most

efficient manner and maintained in the best condition. Therefore, it is necessary

that all personnel responsible for the operation and maintenance of the machine

read the manual thoroughly. By following the instructions in this manual, this

system can be easily and effectively operated, serviced and maintained by

personnel assisted by a brief period of familiarization and training from a Blastrac

technician.

Before attempting to operate, service, or maintain the machine, the personnel

should thoroughly familiarize themselves with the physical makeup of the

machine, be familiar with the major systems of the machine, and have an

understanding of its operation.

The operating and maintenance personnel must obey all the warnings and safety

precautions posted on the side of the machine and stated throughout this

manual. Serious injury to personnel or severe damage to the equipment may

result if the warnings and precautions are not followed, or through careless

handling of this equipment.

Initial operation and maintenance must be done cautiously. Extreme care should

be taken when activating any control devices until the response of the machine

and its various components are clearly understood.

If you have any questions or problems in regard to the operation or capabilities of

this Blastrac machine, please contact:

Blastrac

6215 Aluma Valley Drive

Oklahoma City, OK 73121

405/478-3440

800/256-3440

Or the nearest Service Center.

BLASTRAC/SAWTEC

WARRANTY POLICY

This document is to be used as a guide in determining warranty policies and

procedures for BLASTRAC/SAWTEC products. It is to be used in determining

whether a warranty is justified and also as a procedural guide in completing a

BLASTRAC/SAWTEC Warranty Claim form.

Warranty Responsibility:

The distributor or the end user must prepare a Machine Warranty

Information Card when the machine is delivered. Failure to comply will

make any and all warranties on this equipment null and void. Credit for

warranty repairs will be given only after receipt of the WARRANTY CLAIM

FORM, properly completed with all the required details. Submittal details

are described later in this document.

Warranty Policy:

1. Blastrac warrants its products against defects in material and

workmanship under normal and proper use for a period of 1 year from

the date of delivery as noted on the returned warranty registration card;

in the case of Rental Fleet Machines, date of assignment to Rental

Fleet. Such warranty is extended only to the buyer who purchases the

equipment directly from Blastrac or its authorized distributor. This

warranty does not include expendable parts such as, but not limited to,

blades, blast wheel, wear plats, liners and seals. If the warranty card

is not returned within 30 days of delivery date, the warranty

period is limited to 6 months from the date of delivery as noted on

the warranty registration card.

2. The obligation under this warranty is strictly limited to the replacement

or repair, at Blastrac’s option, of machines and does not include the

cost of transportation, loss of operating time, or normal maintenance

services.

3. This warranty does not apply to failure occurring as a result of abuse,

misuse, negligence, corrosion, erosion, normal wear and tear,

alterations or modifications made to the machine without express

written consent of Blastrac.

4. Warranty request must be submitted in writing within thirty (30) days

after failure.

5. Written authorization to return merchandise under warranty must first

be obtained from Blastrac.

Warranty Policy (Continued)

6. Blastrac reserves the right to inspect and make the final decision on

any merchandise returned under warranty.

7. Blastrac offers no warranty with respect to accessories, including but

not limited to, engines, motors, batteries, tires and any other parts not

manufactured by us but which the original manufacturer warrants.

8. Blastrac reserves the right to make product changes or improvements

without prior notice and without imposing any obligation upon itself to

install the same on its products previously sold.

9. The above warranty conditions can only be altered by Blastrac.

Blastrac must confirm alterations in writing for each specific

transaction.

10. Blastrac reserves the right to establish specific warranty terms for used

or demo machines on an individual transaction basis. Invoices

covering such merchandise will clearly state the provisions of the

applicable warranty for each specific transaction.

11. WE DO NOT AUTHORIZE ANY PERSON, REPRESENTATIVE OR

SERVICE OR SALES OUTFIT TO MAKE ANY OTHER WARRANTY

OR TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH

THE SALE OF OUR PRODUCTS OTHER THAN THOSE

CONTAINED HEREIN.

12. UNDER NO CIRCUMSTANCES SHALL BLASTRAC BE LIABLE TO

CUSTOMER OR ANY OTHER PERSON FOR ANY DIRECT,

INCIDENTAL, OR CONSEQUENTIAL DAMAGES RESULTING FROM

THE USE OF THE PRODUCT OR ARISING OUT OF ANY BREACH

OF ANY WARRANTY OR FOR ANY SPECIAL OR CONSEQUENTIAL

DAMAGES OF ANY CHARACTER, INCLUDING WITHOUT

LIMITATIONS, DAMAGES FOR ANY LOSS OF GOODWILL, WORK

STOPPAGE, OR ANY AND ALL OTHER COMMERCIAL DAMAGES

OR LOSSES.

13. BLASTRAC MAKES NO OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE WITH RESPECT TO THE BLASTRAC

PRODUCTS SOLD PURSUANT THERETO.

iii

Operating Instructions 2-4800DHMKII

Specifications May 2004

1

Section 1

1.1 Specifications

Operating Instructions 2-4800DHMKII

Specifications May 2004

2

1.1 Blast Unit Specifications

** Production Capacity:

1/4” (1cm) Removal 1/8”? 10,000 sq. ft/hr. (929 sq. m/hr.) est.

Cleaning Path: 48" (122 cm)

Blast Wheels: 19-1/2” (50cm) Diameter, Single Sided,

(12) Blades

Abrasive Steel Shot Capacity: 1,200 Lbs. (550 kg)

Travel Speed: 0-370 ft/min. (0-113 m/min)

Overall Length: 18'-6" (564 cm)

Without Blast Unit: 11’-4” ( 345 cm)

Width: 7'-6" (232 cm)

Height: 8’-0” (245 cm)

Weight: 26000 lbs. (11,794 kg)

Engine:

John Deere Model 6125H 12.5L 6 Cylinder

turbocharged and after-cooled w/electronic

control; Tier II emissions

HP: 350 HP (261 kW) @ 2100 RPM

Fuel Type: Diesel

Fuel Capacity: 100 gal (379 L)

Voltage: 12 V DC, 24 V DC, 120 V AC

Dust Collector: 3,500 CFM (100m^3/min) @ 25” S.P.

Filters: (12) 36” Cartridge Style Filters

Note: ** The production rates posted, may vary due to job sight variations. We do not guarantee these

rates. They are approximate rates and should be used accordingly.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

3

Section 2

2.1 General Safety

2.2 Service Mode Safety

2.3 Engine/Mechanical Safety

2.4 Hydraulic Safety

2.5 Dust Collector and Ventilation Safety

2.6 Electrical Safety

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

4

WARNING: All operators and maintenance personnel must read and understand all of the operating

instructions prior to operating or performing maintenance on the machine.

These Blastrac Operating Instructions have been specifically prepared for operating and maintenance

personnel working with the Model 2-4800DHMKII. The information in this manual is intended to provide

an understanding of the 2-4800DHMKII to minimize safety risks and maximize machine performance.

2.1 General Safety

All operating and maintenance personnel must observe all warnings and precautions that are listed in this

manual for the Model 2-4800DHMKII. All safety and warning labels posted on the machine and the

instructions included in these operating instructions must be followed and kept in readable condition.

Refer to drawing number SD-0027 in Section 8.4 for safety decal locations.

A thorough understanding of your 2-4800DHMKII will help ensure that it can be operated efficiently and

with minimized safety risks. No instructions, written or verbal, can be effective without the use of sound

judgment and good work practices in the operation and maintenance of the machine. The U.S.

Department of Labor Occupational Safety & Health Administration (OSHA) provides standards and

regulations relating to the use of equipment on construction sites. The machine operator should be

familiar with, and understand these Regulations and Standards. These Standards and Regulations are

posted on the OSHA Website at www.osha.gov.

1. KNOW YOUR EQUIPMENT.

Do not operate this machine unless you have read the operating instructions carefully. Read any

additional instructions included from other manufacturers. Learn the applications and limitations as

well as the specific potential hazards related to this machine.

2. RECEIVE PROPER TRAINING.

Do not operate this machine unless you have received operational and maintenance training from a

Blastrac representative or from an authorized distributor for Blastrac.

3. CHECK CONDITION OF MACHINE DECALS.

All safety, caution, warning and danger decals must be kept in good readable condition. Replace

damaged decals immediately.

4. PROTECT YOUR FEET.

Observe all applicable local, state and federal safety regulations. Wear OSHA approved foot

protection.

5. PROTECT YOUR EYES.

Observe all applicable local, state and federal safety regulations. Wear OSHA approved safety

glasses.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

5

6. PROTECT YOUR LUNGS.

Breathable silica may be generated by use of this product. Silica can cause severe and permanent

lung damage, cancer, and other serious diseases. Do not breathe the dust. Do not rely on your sight

or smell to determine if the dust is in the air. Silica may be in the air without a visible dust cloud. If air

monitoring equipment for silica is not provided by your employer at your worksite, you MUST wear

appropriate respiratory protection when using or servicing the machine. Consult your employer and

OSHA regarding the appropriate respiratory protection.

7. PROTECT YOUR HEARING.

Observe all applicable local, state and federal safety regulations. Wear OSHA approved hearing

protection.

8. DRESS PROPERLY.

Do not wear loose clothing or jewelry that can be caught in moving parts. Wear protective hair

covering to contain long hair. Wear protective long sleeve shirts and full length pants to protect

against any high velocity shot that may escape through the blast head seals.

9. KEEP CHILDREN AND VISITORS AWAY.

Do not allow any personnel to stand within 50 feet of the machine while in operation. Keep children

and visitors away from the work area.

10. OBTAIN MATERIAL SAFETY DATA SHEET (MSDS) FOR ALL WORK SURFACE MATERIALS.

This includes primers, all coatings, adhesives, crack filling materials, etc. Do not attempt to blast or

remove material without MSDS information. Consult MSDS sheet for hazards information. Be aware

that some materials are explosive as a dust.

11. REMAIN SEATED. KEEP BODY INSIDE OF NORMAL OPERATOR AREA.

The operator must be properly seated in the operator control area before operating any controls.

While operating machine, always keep hands, arms, legs, and head inside the operator area and

remain seated in the operator’s chair until machine has been completely shut down. While, climbing

in and out of the operator’s chair, keep proper footing and balance at all times.

12. STAY ALERT.

DO NOT lose focus on what is coming up in front of the machine while looking at the control panels.

Always be aware of the machine position and movement as you are operating the switches. Watch

what you are doing. Use common sense. Do not operate machine when you are tired or fatigued.

13. DO NOT USE DRUGS, ALCOHOL, OR MEDICATION.

Do not operate machine while under the influence of drugs, alcohol, or any medication.

14. NEVER DISABLE THE EMERGENCY STOP SYSTEM.

Do not modify, disable, or attempt to permanently engage the foot or seat switches. Do not operate a

machine if emergency stop system is not functioning. This could lead to serious injury or death.

15. SAVE THESE INSTRUCTIONS.

Refer to the operating instructions as well as any additional instructions included from other

manufacturers. Never permit anyone to operate the machine without proper instructions.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

6

2.2 Service Mode Safety

Service mode is defined as the state or condition of the 2-4800DHMKII, which minimizes mechanical,

pneumatic, hydraulic and electrical hazards

The 2-4800DHMKII should be put into service mode prior to making adjustments or attempting any

maintenance. The machine should be moved to level ground and shut down according to the shut down

procedures in Section 5.6.

Most industrial and commercial work sites will have already developed their own Lock-Out/Tag-Out

procedures. The site safety personnel should be contacted to establish the procedure to be used. If the

site has no formal Lock-Out/Tag-Out procedure, the operator of this 2-4800DHMKII should be prepared

to implement his/her own procedure including training of all operating and maintenance personnel.

1. MAKE SURE ALL MOVING PARTS HAVE STOPPED.

Before performing any type of maintenance on your Blastrac equipment, be sure that all moving parts

have completely stopped. The blast wheel, for example, may continue to rotate for a period of time

once it has been deactivated. Do not attempt to make adjustments to the feed spout or any control

cage components while the machine is in motion or the blast wheel is operating. All adjustments

must be made when the machine is stationary, the engine is shutdown, the blast wheel and all other

hydraulically driven components are completely stopped.

2. MAKE SURE MOVEABLE PARTS WILL NOT MOVE.

Before performing any type of maintenance on your Blastrac equipment, assure every power source

that can produce mechanical movement has been deactivated and locked in the off position. Assure

all potential energy sources have been minimized. (Example: Move the machine to level ground

before performing any maintenance so machine cannot move by gravitational force.) Assure loose or

freely moveable parts of the machine have been secured against accidental movement. Remove

ignition key to prevent accidental starting. NEVER RELY ON HYDRAULIC COMPONENTS TO

HOLD A LOAD. ALWAYS SECURE MACHINE COMPONENTS AGAINST MOVEMENT WITH

APPROPRIATE DEVICES (BLOCKS, JACK STANDS, ETC.).

3. DEPRESSURIZE PNEUMATIC SYSTEM.

The pneumatic system will remain pressurized after the machine is shut down. Release the air in the

system by slowly opening the valve on the air reservoir located on the rear of the machine OR

release air from the hose reel air gun. Use caution when removing fittings even after depressurizing.

Loosen fittings slowly.

4. ALLOW THE MACHINE AND COMPONENTS TO COOL DOWN.

Many components on the 2-4800DHII have normal operating temperatures that will cause severe

burns if touched. Hydraulic components can reach temperatures of 200 degrees Fahrenheit and

engine components can reach temperatures over 1000 degrees Fahrenheit. Confirm a safe handling

temperature with a measuring device; an infrared thermometer can be used. Wear appropriate

personnel protection before servicing any components

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

7

5. DEPRESSURIZE HYDRAULIC SYSTEM.

Some circuits and components (pumps, motors, hoses, etc.) may remain pressurized after the

machine is shut down. Use extreme caution when working with the hydraulic system. Slowly loosen

the hydraulic fittings near a hydraulic component that needs servicing. Allow the fluid to drip out of

the system until the pressure has been released. Refer to the hydraulic schematic SD-0026 in

Section 8 for circuit details. It is recommended that only qualified hydraulic specialists work on the

system. Contact a Blastrac factory representative before working on any part of the hydraulic

system.

6. AVOID ACCIDENTAL STARTING.

Before servicing the machine, take steps to prevent accidental starting. Remove the key from the

ignition and disconnect battery cables. Be sure others are aware that the machine is being serviced.

2.3 Engine/Mechanical Safety

1. KEEP GUARDS IN PLACE.

All guards must be kept in place and in good condition except during maintenance or when repair

work is being performed. Once maintenance or repair work is complete, be sure all guards are

securely remounted.

2. BLAST HEAD MUST BE SEALED TO WORK SURFACE.

Do not operate the blast wheels unless the blast head seals are compressed against the surface

being cleaned. If there is a catastrophic wheel failure, large metal objects traveling in excess of 200

MPH may come out of the blast head causing severe injury of death. High velocity abrasive may also

be released from the blast head causing injury to surrounding people.

7. AVOID ANY AREAS OR ACTIONS THAT EXPOSE YOU TO CARBON MONOXIDE.

Exhaust gas from gasoline and diesel engines contains dangerous carbon monoxide. Breathing it

can cause unconsciousness and even kill you. Always operate gasoline engine machines in a well-

ventilated area. Do not operate in areas where exhaust fumes could accumulate without wearing

appropriate respiratory protection. Do not rely on your sight or smell to determine if carbon monoxide

is in the air. Consult your employer and OSHA regarding use of appropriate respirator for dangerous

carbon monoxide gases.

8. KEEP WORK AREA CLEAN. DO NOT RUN OVER ANYTHING.

Do not run over any loose objects such as nuts, bolts, gravel, etc. Loose objects could be picked up

by the media recycling system and result in severe damage to the machine. Make sure the work

area is clear from any loose objects before beginning the job.

9. AVOID FLAMMABLE LIQUIDS OR GASES.

This media blast machine produces heat and sparks during operation. Never use machine in

dangerous sites containing flammable, combustible or explosive materials such as lacquer, paint,

benzene, thinner, gasoline, gases, and adhesive agents.

10. AVOID CONTACT WITH HOT PARTS.

Many parts of this machine become hot during operation and remain hot after stopping the engine.

The engine exhaust and turbo charger can reach temperatures of over 1000°F. Do not touch hot

parts before the machine cools or without thermal protection. Do not place flammable objects close

to the machine.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

8

11. REFUEL WITH CARE.

Diesel is extremely flammable. Diesel vapor can explode. Refuel outdoors, in a well ventilated area,

with the blast system in service mode. Never smoke near diesel fuel and keep all flames and sparks

away. If any diesel is spilled, make sure the area is properly cleaned up and dry before starting the

engine.

12. MAINTAIN BLAST MACHINE WITH CARE.

Keep machine clean and follow maintenance procedures to minimize safety risks and maximize

machine performance.

13. REMOVE ADJUSTING TOOLS.

Form a habit of checking to see that tools such as adjusting wrenches are removed from the blast

machine and properly stored before starting the engine.

14. KEEP THE RIGHT PARTS IN THE RIGHT POSITIONS.

Do not operate machine with parts missing or improperly mounted.

15. CHECK FOR DAMAGED PARTS.

Verify all machine guards are in good condition and will function properly before using the machine.

Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any

other conditions that may affect machine operation. A guard or any other part that is damaged

should be properly repaired or replaced by an authorized service center unless indicated elsewhere

in these operating instructions. Do not operate machine if the E-stop, seat switch or foot switch are

not working.

16. NEVER TOUCH THE MOVING PARTS.

Never touch moving parts such as wheels and belts.

17. STOP OPERATION IMMEDIATELY IF ANY ABNORMALITY IS DETECTED.

Stop using machine immediately if any abnormalities are observed during operation. Examples of

abnormalities include unusual noise and vibration.

18. WHEN REPLACING A PART, USE THE SAME TYPE AND QUALITY.

When replacing a component part with a new one, use only the same type and quality of new part.

Never attempt to repair a machine if you are unfamiliar with proper procedures and techniques

required.

19. DO NOT MODIFY MACHINE.

Do not modify machine from its original design without written permission from the manufacturer.

Non-authorized modifications could lead to serious injury or death and void warranty.

20. CLEAN UP ALL LOOSE MEDIA (SHOT).

Loose media (shot) can cause slips and falls on the work surface and surrounding areas. The blast

machine and all areas around the machine should be kept clean. All abrasive leaks should be

repaired immediately and spilled shot should be cleaned up to help keep the work area free of loose

abrasive.

21. AVOID A DANGEROUS ENVIRONMENT.

Do not use machine on sloped (non-horizontal) surfaces over a 12% grade. Keep work area well lit.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

9

22. AVOID RAIN AND MOISTURE.

Do not expose machine or abrasive to rain or moisture.

23. EMPTY UNUSED ABRASIVE.

Always drain unused abrasive and dust from the machine when preparing for storage.

24. AVOID STICKY SURFACES.

Sticky, tar-related and rubber surfaces should be avoided when using Blastrac machinery.

2.4 Hydraulic Safety

1. DO NOT TOUCH HYDRAULIC COMPONENTS.

Hydraulic fluid and components can get hot during normal operation and cause burns. Allow the

system to cool before performing maintenance.

2. DO NOT CHECK FOR LEAKS OR PERFORM MAINTENANCE WHILE SYSTEM IS UNDER

PRESSURE.

Even when the machine is turned off, hoses may still be pressurized. Hydraulic fluid under pressure

is dangerous and can cause serious injury. Pin hole leaks can be almost invisible and can pierce the

skin into the body. If fluid punctures the skin with or without pain, seek medical assistance

immediately.

3. DO NOT OPERATE MACHINE WITH LEAKS.

Keep fittings and hoses tight. Leaking hydraulic fluid is hazardous. In addition to making workplace

floors slippery and dangerous, leaks also contaminate the environment. Always read and understand

the MSDS sheet for the hydraulic fluid before starting machine. Hydraulic fluid is flammable and

when exposed to the proper conditions, it can flash or explode causing damage to equipment and

serious injury or death to personnel in the work area.

2.4 Dust Collector and Ventilation Safety

The 2-4800DHMKII will not operate safely or effectively without a dust collector.

The dust collector aids in the recovery of the abrasive and reduces potentially hazardous dust from the air

stream. If the blast unit is leaving shot on the ground or emitting dust, make sure the dust collector is

operating correctly and the filters are not clogged. The dust collector helps maintain cleaning efficiency

and minimizes the wear on component parts.

The dust hoppers of the dust collection system must not be overfilled. The importance of checking the

dust level cannot be over-stressed. Doing so allows the blast system to help keep the abrasive as clean

as possible, thereby eliminating the greatest cause of wear to the internal components of the machine.

See Section 5.8 for instructions on checking dust levels in the dust collector.

Operating Instructions 2-4800DHMKII

Safety Precautions May 2004

10

1. SHUT DOWN MACHINE BEFORE CHECKING DUST LEVELS.

DO NOT open dust collector doors while machine is in operation.

2. DO NOT TOUCH DUMP DOORS.

DO NOT touch dump doors while machine is dumping dust or in normal operation. Moving parts can

pinch, crush and cut.

3. STAY CLEAR OF THE FAN OUTLETS.

DO NOT look into or touch fan outlets. The fan blades move at high speed and could cut or throw out

loose debris at high speeds. This could lead to serious injury or death.

4. INSTALL FAN OUTLET COVERS.

Always install outlet covers prior to starting job.

5. PROTECT YOUR LUNGS.

Breathable silica may be generated by use of this product. Silica can cause severe and permanent

lung damage, cancer, and other serious diseases. Do not breathe the dust. Do not rely on your sight

or smell to determine if the dust is in the air. Silica may be in the air without a visible dust cloud. If air

monitoring equipment for silica is not provided by your employer at your worksite, you MUST wear

appropriate respiratory protection when using or servicing the machine. Consult your employer and

OSHA regarding the appropriate respiratory protection.

6. EMPTY DUST HOPPER.

Clean the dust hopper when full or at the end of each working day or shift. Many types of dust

(dependent on the surface being cleaned) have the potential to easily ignite when left stored. The

hazards of fires and explosions are minimized when the dust is removed as recommended. Dispose

of waste in accordance with all applicable local, state and federal regulations.

7. DO NOT EXPOSE SYSTEM OR DUST TO IGNITED MATERIALS.

Do not smoke within 50 feet of the machine or dust.

8. USE WITH APPROPRIATE VACUUM HOSE.

Do not use worn vacuum hoses with holes that could cause a loss of vacuum system efficiency.

2.5 Electrical Safety

1. DO NOT ATTEMPT TO REPAIR ELECTRIC SYSTEM. HAZARDOUS 120 AC VOLTAGE IS

PRESENT.

Due to the complexity of the electric control system, Blastrac recommends that only qualified

technicians attempt to repair electric components.

2. DO NOT CONNECT OR DISCONNECT POWER CABLES WHILE UNDER LOAD.

Do not disconnect the power cords to the blast head while the machine is on.

3. CHECK STRAIN RELIEF CLAMPS.

Cable strain relief clamps are provided for all power cabling. Assure that these strain relief clamps

are secured to the frame of the equipment with the hardware provided prior to energizing the

equipment.

Operating Instructions 2-4800DHMKII

Operator Responsibilities May 2004

11

Section 3

3.1 Operator Responsibilities

Operating Instructions 2-4800DHMKII

Operator Responsibilities May 2004

12

3.1 Operator Responsibilities

1. The owner/operator is responsible for the observance of all safety precautions expressed in these

operating instructions.

2. The owner/operator should be trained by a Blastrac Technician for the operation and maintenance of

Blastrac equipment.

3. The owner/operator should provide the necessary blasting media in accordance with the

recommendations of a Blastrac Technician so that the 2-4800DHMKII will operate at its maximum

efficiency.

4. The owner/operator must perform all maintenance and basic repair functions as stated and described

in these operating instructions.

5. The owner/operator should maintain an inventory of wear parts as outlined in these operating

instructions.

6. The owner/operator must dispose of all dust collector refuse according to the appropriate local, state

and federal guidelines.

7. The owner/operator is responsible for maintaining a safe work environment under OSHA, federal,

state and local guidelines.

Operating Instructions 2-4800DHMKII

Description and Function May 2004

13

Section 4

4.1 General

4.2 Engine

4.3 Hydraulic System

4.4 Pneumatic System

4.5 Blast Unit – Abrasive Cleaning Head

4.6 Blast Unit – Abrasive Control Valve

4.7 Blast Unit – Rebound Chamber (Plenum)

4.8 Blast Unit – Upper Reclaim Assembly

4.9 Blast Unit – Abrasive Seals

4.10 Blast Unit – Chassis

4.11 Blast Head – Adjustment System

4.12 Dust Collector – Ventilation System

4.13 Dust Collector – Filter Chamber

4.14 Dust Collector – Hopper and Access Doors

4.15 Dust Collector – Blowers

4.16 Dust Collector – Magnehelic Gauge

4.17 Dust Collector – Pulse Pressure System

4.18 Cleaning Media (Abrasive shot)

4.19 Electrical Control System

4.20 Electrical Control System – Multi-Display Panel

4.21 Electrical Control System – Joystick Panel

4.22 Electrical Control System – John Deere Panel

4.23 Electrical Control System – Dash Panel

4.24 Electrical Control System – Dust Collector Rear Panel

4.25 Electrical Control System – Blast Head Panel

4.26 Electrical Control System – MCP (A/B) Panel

Operating Instructions 2-4800DHMKII

Description and Function May 2004

14

4.1 General

The 2-4800DHMKII is an all inclusive horizontal surface preparation, closed cycle, shot blasting system

designed for high production jobs. The system cleans a 48 inch path and holds 1,200 pounds of

abrasive. Major applications include removing dirt, paint, and other coatings from either concrete or steel

surfaces. Typical work surfaces include bridges, highways, ship decks, and industrial plant and

warehouse floors.

The blast unit located on the front of the machine directs high velocity, metallic abrasive towards the work

surface. The impact of each individual particle causes the surface to fracture and become loose. The

abrasive and the loose surface particles are then directed upward due to the force of the impact and a

strong airflow created by the dust collector. The mixture of shot and contaminants enter the rebound

plenum and continue upward movement until directed into a specially designed chamber called the

separator. Inside this chamber, an air wash cleans the abrasive and allows the contaminants to be

extracted back to the dust collector located at the rear of the 2-4800DHMKII. The clean abrasive is then

gravity fed to one of two elevators, which deliver the abrasive back to the shot hopper, and the process

repeats.

The machine is equipped with a front end lift system that can raise up the entire blast unit for easier

transportation. In addition to the lift system the blast head can be raised and lowered horizontally for

ideal sealing to the work surface. Lastly, a side shift function allows the operator to shift the blast head

into multiple positions across the width of the machine. The blast head is able to blast within 5 inches

from a wall on either side of the machine.

The 2-4800DHMKII is equipped with its own internal Dust Collector system. This allows the complete

blast system to be efficiently operated by a single operator.

4.2 Engine

The 2-4800DHMKII is powered by a 12.5 liter 6 cylinder 350 horsepower turbo charged John Deere

diesel engine which drives the hydraulic, electrical and pneumatic systems. The machine has a 100

gallon diesel fuel capacity. Most major components, such as the blast wheels, the ground drive wheels

and steering, bucket elevators, blast head lift, level and side shift systems, dust collector blowers and

hopper dump gates are hydraulically powered. Some smaller components, such as the abrasive control

valve, air cooler fan, the control panel and hydraulic control system are electrically powered. The dust

collector pulse system and blow-off nozzle are pneumatically powered components. The engine system

includes a heat exchanger which cools the engine and hydraulic system fluids.

4.3 Hydraulic System

The hydraulic system consists of five main circuits, four closed loop circuits and one open loop circuit.

The closed loops, or hydrostatic circuits, are the Blast Wheels, Blowers, Elevators and Ground Drive.

The open circuit is reserved for auxiliary systems such as cylinder and steering functions in addition to

the charge loop. Refer to the hydraulic schematic drawing number 330-SD026 in section 8.

Operating Instructions 2-4800DHMKII

Description and Function May 2004

15

4.4 Pneumatic System

The pneumatic system is powered by the air compressor directly mounted on the John Deere engine and

is used primarily to provide compressed air to pulse clean the dust collector cartridges. The pneumatic

system consists of a compressor, heat exchanger, reservoir and air valves.

Compressed air is stored in the reservoir and pulsed into the cartridges for a set duration and time

sequence between pulses. The dust collector panel on the rear of the dust collector contains the pulse

timer board that controls the pulse conditions.

Electro-pneumatic solenoid valves release air from the diaphragm valve which allows the compressed air

into the four pulse pipes. A single bank of three cartridges pulse according to the conditions set in the

pulse timer board.

The system also includes a blow-down nozzle mounted on the front of the blast head that may be used

for cleaning the machine during service intervals. Refer to the pneumatic schematic drawing number

330-SD028 in Section 8.

4.5 Blast Unit – Abrasive Cleaning Head

The center of the abrasive cleaning head is two 19-1/2” diameter twelve-bladed blast wheels that

accelerate abrasive toward the surface being cleaned. The center fed centrifugal blast wheels propel the

abrasive by centrifugal force at a speed of more than 200 mph and cover a 48 inch blast pattern. The

blast wheels are driven by two direct drive hydraulic powered motors.

The blast wheels are enclosed in an abrasion resistant housing with replaceable liners. These liners are

located in areas where the most wear is present. The operator must change them periodically to protect

the housing.

Abrasive material or shot/grit is gravity fed to the center of the wheel and is accelerated by the impeller

segments and directed through the control cage. The control cage determines where the abrasive is

introduced onto the rotating blades of the wheel which in turn determines where the abrasive is being

“aimed”. More information on adjusting the control cage is discussed in section 6.4, Blast Pattern Setup.

The control panel includes pressure gauges that read the pressures in pounds per square inch (psi) at

the blast wheel pumps. The pressures at the pumps are directly related to the amount of abrasive being

fed into the system. The pump will work harder when delivering more abrasive, which causes the pump

to require more pressure. Controlling this pressure is the key to achieving optimum efficiency. More

information is provided in section 6.2, Blast Cleaning.

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Blastrac 2-4800DH Owner's manual

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