Blastrac 1-16DB4-V2, Service Manual

Page 1: ...SERVICE MANUAL 1 16 DB4 V2 VERSION 1 1 www blastrac com 1 800 256 3440...

Page 2: ...of the Machine 10 Tie Down Locations 11 5 Operation 12 Preparation for Operation 12 Operator Awareness 13 Engine Startup 14 Operation Adjustments 17 Operation Sequence 18 Dust Collector Function 20 D...

Page 3: ...ise level is 85 dB A or more the machine operator and persons working near the machine must wear sound insulating equipment However it is the contractor s responsibility to ensure the safety of their...

Page 4: ...information To read these instructions after work has commenced is too late This particularly applies to incidental activities such as setting up the equipment carrying out maintenance work or trainin...

Page 5: ...f the facilities for reporting and fighting fires Fundamental Duties Work on the machine may only be undertaken by trained personnel Only trained personnel may be employed Note the statutory minimum a...

Page 6: ...e side of the blast housing Do not operate this equipment on wet surfaces or in the vicinity of flammable liquids 6 Only operate the machine when all safety devices and related safety equipment are pr...

Page 7: ...der to carry out maintenance repair or adjustment it must be secured against unintended restart See page 8 for specific details of the Safety Off Position Always dispose of the contents of the dust ba...

Page 8: ...finition The machine is in a safe condition where it cannot be a hazard Putting the equipment in the Safety Off Position involves Close the shot valve Switch off the machine Wait for all drives to sto...

Page 9: ...ves The blast wheel is a paddle wheel design that is pulley driven by a mechanical clutch Shot feeds through the shot valve to the blast wheel The shot and debris rebound to the dust separator and the...

Page 10: ...the abrasive from the machine and clean the dust out of the dust collector Always drive carefully and in a manner to avoid the machine shifting Tighten the machine to the vehicle or trailer with strap...

Page 11: ...Tie Down Locations There are 4 tie down locations as show below Front Tie Downs Side Tie Downs 11...

Page 12: ...reign materials and remove them Check the blast wheel blades liners and fastening screws for damage and wear Important Note The blades should be changed before they wear past the vanes on the blast dr...

Page 13: ...tor awareness will create down time and can prove to be very costly When the shot valve is open the machine is throwing shot Therefore you must be sure the shot valve is closed prior to starting as we...

Page 14: ...safety regulations given in this manual 14 Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless and colorless and can cause injury or death if inhaled Do not use equipmen...

Page 15: ...ows engine oil pressure in pounds per square inch ENGINE HOURS shows engine operating hours ENGINE TEMP shows the current engine temperature of engine WARNING LIGHTS CHARGE FAILURE lights when alterna...

Page 16: ...after engine turns over 4 Place throttle to full open position and operate as normal Hot Startup Procedure 1 Turn ignition to start position Note Due to the engine being at operating temperatures you...

Page 17: ...t the amount of vacuum pulled through the blast housing It can be used to fine tune air flow to the specific application 3 Pinch Bar The pinch bar clearance must be checked before each operation For b...

Page 18: ...e motion 6 Start the machine moving forward and slowly open the shot valve The slower the machine travels while the shot valve is open the deeper the profile 7 When coming to the end of a pass close t...

Page 19: ...8 Only operate this machine when sitting in the operator seat DO NOT OPERATE THIS MACHINE WHEN STANDING IN FRONT OF IT Figure 4 19...

Page 20: ...r portion of the dust collector where it exhausts to the open atmosphere through the silencer box The dust that was trapped on the external surface of the filters is periodically removed by pulsing th...

Page 21: ...Dust Collector Parts 21 Pulse Valve Tank Blow Down Tube Dust Collector Outlet Venturi Filter Cartridge Dust Collector Inlet Dust Bag Figure 5...

Page 22: ...mplete the maintenance check list Safety Shutdown The machine has to be in its Safety off position before starting repair work See page 8 The local safety regulations are valid in all cases regarding...

Page 23: ...ck Side Liner 1 2 P000831 1 Pinch Bar Inspection Plate 1 3 WKIT1665 Dovetail Blades 4 per set 1 4 WP123715 Blade Keepers 1 23 The key must be in the off position and all rotating parts must come to a...

Page 24: ...d shot out of the threaded hole in the end of the blade 6 Use a slide hammer to pull the blade out of the blast head Important Note A slide hammer is provided with all machines containing a pinch bar...

Page 25: ...emoval Installation and Re Positioning Figure 7 ITEM NO PART NUMBER DESCRIPTION QTY 1 08300093 RETAINER PINCH BAR 1 2 08300042 INDEXER PINCH BAR 1 3 4 P002712 RETAINER OUTER PINCH BAR 1 5 WP033711 PIN...

Page 26: ...descriptions and locations 1 Remove Item 3 Retainer Outer Pinch Bar 2 Remove Item 1 Retainer Pinch Bar Indexer 3 Remove Item 2 Indexer Pinch Bar 4 Insert slide hammer into the threaded hole in the end...

Page 27: ...0830 COVER PLATE BLAST HOUSING 1 4 WP093716 LINER SIDE REAR OUTSIDE LOWER SLL 1 5 WP053708 LINER SIDE REAR UPPER OUTSIDE SLL 1 6 WP053704 LINER SIDE FRONT INSIDE OUTSIDE UPPER SLL 1 7 WP093707 LINER S...

Page 28: ...4 Cover Plate a Remove the five nuts which connect the cover plate Item 6 to the housing b Remove the cover plate 5 Side Liners Remove the outside side liners Items 8 and 9 The side liners may be fir...

Page 29: ...WP113715 Liner Top Curved SLL 1 2 WP053704 Liner Side Front Inside Outside Upper SLL 1 3 WP053712 Liner Side Rear Inside Upper SLL 1 4 WP093706 Liner Side Lower Inside SLL 1 5 02110015 Bearing FLG3 1...

Page 30: ...ons 1 Remove nuts from bearing Item 5 and remove bearing 2 Remove the bolt retainer Item 6 3 Remove the inside side liners Items 2 and 3 Remove two nuts securing lower inside liner Item 4 and the line...

Page 31: ...12 Liner Back Wall SLL 1 5 WP113715 Liner Top Curved SLL 1 6 WP053704 Liner Side Front Inside Outside Upper SLL 2 7 WP053712 Liner Side Rear Inside Upper SLL 1 8 WP093706 Liner Side Lower Inside SLL 1...

Page 32: ...nd efficiency of the system Improper vacuum can cause poor abrasive cleaning which in turn increases blast wheel and liner wear An important fact that is often ignored or misunderstood is Filter Cartr...

Page 33: ...nd switchedoff If theengineiswarm switch off the engine andcheckthelubricatingoillevelafter5 minutes Iftheengineiscoldyoucancheck it immediately Al Becarefulofhotlubricatingoil Dangerof leJ scalding P...

Page 34: ...h e n e w D E U T Z o r i g i n a l f i l t e r c a r t r i d g e l i g h t l y S c r e w o n n e w f i l t e r b y h a nduntilthegasketisin placeandthentighten withatorqueof15 17Nm Fasten clamps of t...

Page 35: ...an foil Work on the fuel system may only be car ried outin anabsolutely clean environment Contamination ofthe air such asdirt dust moisture etc must beavoided Additionalventing of the fuel system by a...

Page 36: ...Check for leaks after starting theengine...

Page 37: ...lamps when twist protection mounted optional Loosenandunscrewfiltercartridgewithtool or der number 170050 Catch any escapingfuel Cleanthesealingsurfaceofthefiltersupport with a lint free clean cloth O...

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Page 39: ...l pre filter holder 2 Fuel filter insert 3 Water collectionvessel 4 Water drain tap 5 Fuel pump 6 Sealingsurface 7 Venting screw Shutoffthe fuelsupply totheengine withhigh level tank Place avessel und...

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Page 41: ...haff andchopped strawinthearea oftheen gine Coolantleaks Lubricating oil leakage Fuelleaks Because of the different application conditions cleaningdependsonthedegreeofdirtcontamina tion Cleaning with...

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Page 43: ...safety car tridge 4 Insertnewsafetycartridge screwonhexag onal nut Insertfilterelement 3 mounthood 2 andfix with clamping yoke 1 Care and maintenance work Suction system Maintena nee indicators for dr...

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Page 45: ...nglestotheV belt 2 evenly untilyouhearorfeelthe spring snap in Lift themeasuring device carefullywithoutalter ing the positionoftheindicator arm 1 Readthemeasuredvalueatthepointofinter section arrow s...

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Page 47: ...gaging the clutch for short periods 1 second at intervals long enough to prevent excessive heat buildup in the friction discs With extremely high loads the engine may have to be operated at higher spe...

Page 48: ...f operation Clutch Adjustment Frequency 1 As clutch wears the hand lever force required to engage clutch will decrease 2 The need to readjust the clutch is indicated when the handle force has decrease...

Page 49: ...Grease Points Apply two pumps of high temperature grease every 8 hours Follow the instructions listed on page 40 for lubricating the clutch Figure 11 42...

Page 50: ...BLASTRAC RS IN SURFACE PREPARATION Figure 12 43...

Page 51: ...Red H 108 J 109 14AWGPu _ 16 AWG Ye ff 8 1 1Ck II Ao Swilch 1 T Switch PlressureSwi Groond 110 L 111 112 N m 16 AWG Ye llow 16 AWG Ye ll wjBlue 1B AWG Y e llolNJOranne S arn r p 114 12 AWG Red Blad u...

Page 52: ...1 4 A W G F u l l l l e T o F J 1 R e d 1 2 A l G T 0 P I P n d er SW i1ch NJO S e n d e r S w i t c h N J C...

Page 53: ...12 H Ground 4 16 AWG Yellow Aux Switch I 16AWGRed Solenoid Aux Swf ch I 5 Temp Swi h 6 16 AWG Yellow Bue T emp S witdl Tempera 16AWGBladl D 7 16 AWGYellcm Orange Grol lld 31 J H1m 11 H Pres SUre9Mtch...

Page 54: ...OJ ru d J I II a l l L l t Ol Ill Vl CJi fl T ru 0 L l Ill LL l 0 ll1 H IJ 0 ci d l V1 0 0 L Ill l_ OJ l _ LJ I L Qt 1 1 L n LI j11 n L P J _ _ _l r t l l u w u d d d r I I I I o 1 II 0 Ill l rri 7 m...

Page 55: ...a B J I I o I I I I Q o f I I I n ii1 0 I LI JI ii Cl 0 L I D IY I I I I I I I I I i Ii i c1 f ot I D P d L L J l c Q I r fJ d n n n I 46...

Page 56: ...DESCRIPTION QTY 1 CP 10695 BELT 3VX710 2 STRAND 1 2 CP 10694 BELT 3VX560 4 STRAND 2 3 CP 10693 BELT 3VX750 3 STRAND 2 4 2100002 BEARING 1 PILLOW BLOCK 2 5 2110004 BEARING 1 1 4 2 BOLT FLANGE 1 6 21000...

Page 57: ...BLASTRAC VATORS IN SURFACE PREPARATION Blast Head Assembly Figure 14 48...

Page 58: ...NCH BAR 1 21 8300044 RETAINER PINCH BAR 1 22 8300093 RETAINER PINCH BAR INDEXER 1 23 WP123717 BLASTWHEEL DOVETAIL 1 24 8300171 SEAL SHAFT BEARING 2 25 2110015 BEARING BLAST WHEEL 2 26 3500001 3 8 BEVE...

Page 59: ...7 Contact Blastrac NA 13201 North Santa Fe Avenue Oklahoma City OK 73114 Tel 800 256 3440 Fax 405 478 8608 www blastrac com 50...

Page 60: ...noted on shipping receipt Hand Tool Products Blastrac warrants its BLASTRAC Hand Tool Products including hand grinders and accessories against defects in material and workmanship under normal and pro...

Page 61: ...motors batteries tires and all other parts See component manufacture warranty 7 Blastrac reserves the right to make product changes or improvements without prior notice and without undertaking any obl...

Page 62: ...very date entered with product registration Failure to comply will make any and all warranties on the equipment void after 6 months OWNER END USER S REFERENCE INFORMATION Delivery Date Delivering Dist...