2-45D
Table of contents
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Operating Instructions
2-45D
MAN-2-45D-EN (Freightliner)
Technical Data
Safety Instructions
General
Transport
Initial Operation
Operation
Maintenance
Electrical & Hydraulic Systems
Fault Diagnosis
Spare parts
Design and specicati ons are subject to
change w ithout notice - November 2008
2-45D Operating Instructions
Technical data
Contents Chapter 1
1.1 Rating
1.2 Unit specifications
1.3 Operative range and correct usage
1.4 Machine type designation
1.5 Advice for operators of blast cleaning machines
1
45D
2 x 25 kW
Operating Instructions 2Technical data
1.1 Rating
Unit / designation : Blastrac blast cleaning machine
Machine type : 2-45D
Manufacturer : Blastrac BV
Utrechthaven 12
NL-3433PN Nieuwegein
THE NETHERLANDS
1.2 Unit specifications
Dimensions:
Machine 2-45D
Length 1576 mm
Width 1420 mm
Height 1415 mm
Weight 1650 kg
Power consumption (hydraulic system):
The indicated values correspond to normal operating conditions.
Power consumption Flow and pressure
Blast wheel drive
Magnet drum motor 0,8 kW 4,8 l/min at 100 bar
Blower motor 22 kW 63 l/min at 210 bar
Required hydraulic flow: min. 200 l/min at 250 bar
Required cooling capacity: min. 22,5 kW
Required oil tank: min. 350 liters
Required drain lines for blast wheel motors: min. 1/2"
.....
Please contact Blastrac to get more details about other (hydraulic)
requirements for the 2-45D machine.
2 x 64 l/min at 235 bar
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2-45D Operating Instructions
Technical data
Rated speed
Blast wheel speed 4000 min-1
Magnet drum speed 160 min-1
Blast wheel size : 2 x 349 mm Ø
Working width : 1150 mm
Required drive speed : 0 - 5,0 km/h
Blast cleaning output : up to 2000 m²/h
Dust hose connection : 2 x 150 mm Ø
Recommended abrasive : Shot 460-550
Abrasive consumption : 0,1 - 0,5 kg/m²
Recommended filter unit : 2-45 TDC
1.3 Operative range and correct usage
The 2-45D is exclusively designed to clean dry, frostfree horizontal surfaces. The machine may not be
used for other purposes. The manufacturer will not
be liable for damage resulting from such incorrect
usage. In these cases the user assumes all risks.
3
45D
number of blastwheels
blast cleaning width
product code
Operating Instructions 2Technical data
1.4 Machine type designation
2 - 45 D
1.5 Advise for operators of blast cleaning machines
In accordance with the accident prevention
regulations for blast cleaning work (VBG 48) the
operator must provide operating instructions for
blast cleaning work in a form and language that is
understandable.
The blast cleaning machine Operating Instructions
are only part of these operating instructions. Please
consult the current accident prevention regulations
for the precise content.
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2-45D Operating Instructions
Safety instructions
Special work within the scope of use of the equipment and
Contents Chapter 2
2.0 Warnings and symbols
2.1 Organisational measures
2.2 Personnel selection and qualification
2.3 Safety precautions applicable to different operating conditions
2.4
maintenance activities as well as repairs during operation
2.5 Definition of the Safety off position
2.6 Particular dangerous aspects of the equipment
2.7 Hydraulic and electrical engineering regulations
1
45D
Operating Instructions 2Safety instructions
2.0 Warnings and symbols
The following denominations and symbols are used in the Operating
Instructions to highlight areas of particular importance:
Symbol of operational safety.
In these Operating Instructions this symbol will be
shown next to all safety precautions that are to be
taken in order to ensure prevention to life and injury.
Follow these instructions and take special care in
these circumstances. In addition to these
instructions, the general safety precautions and
accident prevention guidelines are also to be
followed.
Particular details regarding the economical use of
the equipment.
Information, instructions and restrictions with regard
to possible risks to persons or to extensive material
damages.
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2-45D Operating Instructions
Safety instructions
Warning against dangerous voltages.
Indications relating to protective devices in electrical
appliances.
Indications where consultation with the
manufacturer is required.
Instructions relating to periodical checks.
Reference to important instructions contained in the
Operating Instructions.
2.1 Organisational measures
The Operating Instructions are to be kept near the location
where the machine is located and must be within reach at all
times!
In addition to the Operating 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.
3
45D
Operating Instructions 2Safety instructions
The Operating Instructions must be supplemented by instructions
including the duty to supervise and report relating to particular
working practices, for example work organisation, work procedures
and personnel allocation.
Personnel entrusted with working with the machine must have read
the Operating Instructions before starting work, in particular the
Safety Instructions chapter. To read these instructions during work
is too late. This particularly applies to incidental activities such as
setting up the equipment, carrying out maintenance work or training
staff to work with the machine.
From time to time the working practices of the staff are to be checked
regarding awareness of safety and hazards.
Personnel must tie back long hair and not wear loose clothing or
jewellery including rings. There is a risk of injury through getting stuck
or being drawn into moving machinery.
Use personnel protection equipment if necessary or required by
regulations! Take notice of all safety and hazard notices on the
machine!
All safety and hazard notices at or on the machine must be kept
complete and legible!
If safety-critical changes occur to the machine or its working
method, the machine must be shut down immediately! The cause of
the fault must be established immediately!
Changes, add-ons or conversions to the machine which might impair
safety must not be undertaken without the manufacturer’s
permission!
This applies in particular to the fitting and adjustment of safety
devices as well as to welding on load-bearing parts.
Spare parts must comply with the technical requirements specified
by the manufacturer. This is always guaranteed if original spare
parts are used.
Intervals for recurring checks and inspections specified in these
Operating Instructions must be complied with!
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2-45D Operating Instructions
Safety instructions
To perform maintenance work correctly it is imperative to be equipped
with the proper tools for the task in question.
The location and the operation of fire extinguishers must be made
known on each building site!
Take note of the facilities for reporting and fighting fires!
2.2 Personnel selection and qualification
Fundamental duties :
Work on the machine may only be undertaken by reliable personnel.
Only trained personnel may be deployed. Note the statutory
minimum age! Specify clearly the responsibilities of personnel for
operation, setting up, servicing and maintenance work!
Make sure that only authorised personnel operate or work on the
machine!
Define responsibilities of the machine operator also regarding to
traffic safety regulations and empower him to decline instructions
from third parties which are not complying with the safety
requirements!
Personnel being trained or made acquainted with the equipment may
only be deployed on the machine under constant supervision of an
experienced person!
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45D
Safety precautions applicable to different operating
Operating Instructions 2Safety instructions
2.3
conditions
Ban any method of working that impairs safety!
Only operate the machine when all safety devices and related
safety equipment, e.g. detachable safety devices, emergency
stops and suction devices are present and operational!
Check the machine visually for any damage and defects at least
once a day!
In the event of operational malfunctions the machine must be shut
down immediately and secured, and the fault must be rectified!
Secure the work area around the machine in public areas
providing a safety distance of at least 2m from the machine.
Before switching on the machine make sure that no-one can be
endangered when the machine starts up!
Do not switch off or remove the exhaust and ventilation devices when
the machine is running!
All persons in the proximity of the machine must wear ear
protectors, safety glasses with lateral protection as well as safety
shoes. The operator is obliged to wear close-fitting protective
clothing.
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2-45D Operating Instructions
Safety instructions
Special work within the scope of use of the equipment and
2.4
maintenance activities as well as repairs during operation
Mechanical servicing work:
Put the machine in the Safety off position as described in chapter
2.5 for any servicing work on the machine in order to prevent the
machine from being switched on accidentally.
Please follow any special safety instructions in the various chapters
on servicing the machine.
See chapter 7.1 - 7.9.
Adjustment, servicing and inspection work and time limits
specified in these Operating Instructions as well as any information
on the replacement of parts and equipment must be undertaken
and/or complied with!
These activities may only be undertaken by qualified personnel.
Do not use any aggressive cleaning materials!
Use lint-free cleaning cloths!
Always tighten any screw connections that are undone during
servicing and maintenance work!
If safety devices need to be dismantled during setting up, servicing
and repairs, these safety devices must be reinstalled and inspected
immediately after completion of the servicing and repair work.
Make sure that process materials and replaced parts are
disposed of safely and in an environmentally-friendly manner!
Hydraulic servicing work:
Make sure that hydraulic components used for replacement purposes
comply with the original parts and are correctly adjusted if necessary.
For safety notes see 2.7 Hydraulic and electrical engineering
regulations.
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45D
Operating Instructions 2Safety instructions
2.5 Definition of the Safety off position
Definition:
The machine is in a safe condition when it cannot generate any
hazard.
Putting the equipment in the Safety off position means:
Close the shot valves.
Switch off the blast machine.
Switch off the dust collector.
Wait for standstill of all drives.
Disengage the hydraulics - Switch off PTO.
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2-45D Operating Instructions
Safety instructions
2.6 Particular dangerous aspects of the equipment
Any machine, if it is not used according the regulations, may be
hazardous for operating, setting-up and service personnel. The
operating authority is responsible for compliance with the
safety regulations during operation and maintenance of safety
devices supplied with the machine as well as the provision of
appropriate additional safety devices!
1. Blast housing outlet
Danger of injury!
Abrasive leaves housing with
high speed!
Moving parts!
Lift and cant the machine only
when it is in Safety off position.
It is not allowed to stay within
the working radius of the
machine!
2. Wheels
Danger of injury!
Moving parts!
It is not allowed to stay within
the working radius of the
machine!
9
45D
equipment or operating materials may only be
persons
skilled hydraulic
hydraulic engineering
equipment or operating materials may only be
persons under
as well as
.
. Use only
hoses and pipe work that are sized and marked in accordance with
Operating Instructions 2Safety instructions
2.7 Hydraulic and electrical engineering regulations
Work on hydraulic
undertaken by a skilled hydraulic engineer or by trained
under the guidance and supervision of a
engineer as well as in accordance with the
regulations.
Work on electrical
undertaken by a skilled electrician or by trained
the guidance and supervision of a skilled electrician
in accordance with the electrical engineering regulations.
Hoses and pipe work can be under hydraulic pressure
Temperature of the components can be above 37° C
the overall power consumption of the machine.
The hydraulic and electrical equipment for the plant must be
inspected regularly. Please note in particular the specified
recurring inspections. Defects such as loose connections or
scorched hoses and cables must be rectified immediately. Call a
skilled hydraulic or electrical engineer or our Customer
Services.
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 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.
Only start work once you are familiar with the hydraulic and
electrical engineering regulations that apply to your area.
Only use voltage seekers that comply with the regulations when
troubleshooting. From time to time check voltage seekers to ensure
that they are operationally efficient.
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2-45D Operating Instructions
General
Contents Chapter 3
3.1 Introduction
3.2 Operating instructions
3.3 Hydraulic connections
3.4 Care and maintenance
3.5 Scope of supply
3.6 Description
3.7 Blast wheel
3.8 Separator, magnetic drum and hopper
3.9 Abrasive sealing
3.10 Air suction and filter system
3.11 Abrasive media
1
45D
Operating Instructions 2General
3.1 Introduction
Blastrac wants to thank you for your decision to employ the blast
cleaning machine 2-45D for the treatment of horizontal surfaces.
The machine has a closed abrasive circuit with dust separation. This
comprehensively avoids damaging the environment and endangering
the operating staff.
The 2-45D is designed to remove coatings, non-skid, epoxy, bitumen
and asphalt on different types of horizontal surfaces.
3.2 Operating instructions
This manual has been written to support the operating personnel on
learning the functioning of the machine and to guarantee optimum
operation and maintenance.
Therefore it is important that all persons operating and
maintaining the machine read this manual carefully and
understand it fully.
The supplied machine has been manufactured for being employed in
the user’s country. All descriptions and notes have been formulated in
the language of the user’s country or in English in accordance with
the statutory regulations, or shown as pictograms. If the customer
deploys personnel with little knowledge of the language of the user’s
country, appropriate instruction and training must be provided.
Before using the machine personnel must be familiar with how
to operate the machine, with all important components, with the
method of working and with its dimensions.
Blastrac offers a course on the use of the machine in order to make
the operating and maintenance personnel familiar with all elements of
the blast cleaning machine.
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2-45D Operating Instructions
General
eration must wear
ear protectors, safety glasses with lateral protection and safety
fitting protective
Initial commissioning of the machine must be carried out very
carefully. The machine operator must fully understand the sequence
of commissioning of the individual parts and their functioning.
All persons in the proximity of the machine in op
shoes. The machine operator must wear close-
clothing.
3.3 Hydraulic connections
Flow Pressure
Blast wheel drive 2 x 64 l/min 210 bar
Magnet drum motor
Blower motor 63 l/min 180 bar
Required hydraulic flow: min. 200 l/min at 230 bar
Required cooling capacity: min. 50 kW
Required oil tank: min. 350 liters
Required drain lines for blast wheel motors: min. 1/2"
.....
Please contact Blastrac to get more details about other (hydraulic)
requirements for the 2-45D machine.
3.4 Care and maintenance
Special attendance and regular maintenance of the machine and its
parts are imperative for functioning and safety.
In order to prevent unnecessary downtimes it is recommended to
keep original spare and wear parts on stock as listed in the
maintenance box.
A list of contents of the maintenance box is provided in Chapter 10 to
enable the above-mentioned work to be carried out quickly.
8 l/min 100 bar
3
45D
Operating Instructions 2General
3.5 Scope of supply
Scope of supply of the machine:
Blast cleaning machine (2-45D)
Dust hose
Operating instructions (2 x)
Machine adapter
Tow behind magnet sweeper (2-45TBS)
3.6 Description
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Fig. 3.1
Separator incl. hopper 6 Feed spout
2 Blast wheel motor 7 Blasthead, rubber sealing, brush sealing
3 Magnetic drum 8 Recovery duct
4 Blast housing 9 Transport castor
5 Filter connection
2-45D Operating Instructions
General
The Blastrac blast cleaning machine 2-45D is a downward blasting
machine with a closed abrasive circuit designed for the pre-treatment
of 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.
Like many revolutionary inventions the blast wheel method is based
on a simple principle: after mechanical pre-acceleration the abrasive
is thrown onto the surface at high speed by the blast wheel. Once the
abrasive has impacted on the surface it rebounds into a recovery
duct. The recovery duct deflects the abrasive into an air current
separator. Here dust and other contaminants are removed from the
abrasive so that only abrasive containing a very small amount of dust
is fed into the abrasive storage hopper for re-use by the blast wheel.
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.
Fig. 3.2
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Operating Instructions 2General
3.7 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.
Fig. 3.3
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 flow of abrasive.
1 Control cage
2 Impeller
3 Blades (set of 6)
4 Blast wheel
6
2-45D Operating Instructions
General
3.8 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. This magnetic drum functions as a
second separator for bigger particles and feeds the cleaned abrasive
back to the abrasive storage hopper.
Two wire meshes are fitted to prevent any coarse contaminants from
getting into the blast wheel. In order to clean the wire mesh drawers,
the drawers can be removed from the sides.
Fig. 3.4
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
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Operating Instructions 2-45
General
3.9 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 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 functionability of the machine. The adjustment
can be carried out by means of shaft nuts at the front and rear wheels.
Fig. 3.5
1 Side brush housing
2 Side magnet
3 Front magnet
4 Front brush
5 Front seal rubber
6 Side seal rubber
7 Rear brush
8 Airflow adjuster
8
2-45D Operating Instructions
General
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.
Fig. 3.6
1 Brush housing
2 Side brush spring
3 Guide
4 Felt seal
5 Side brush inner
6 Side brush outer
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D
20 mm) is of
utmost importance. There must be no leaks in the blast housing,
onnection points must be sealed carefully and the dust hose
The filter housing must be sealed properly and all sealings must
If dust leaves the filter unit instead of clean air, this is a sign that
the filter cartridges are either damaged or not fixed correctly
Operating Instructions 2-45
General
3.10 Air suction and filter system
The sucked-in air streaming through the complete system when the
blast cleaning machine and the filter unit are in operation 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 dust from the re-useable abrasive
Transport of dust to the filter unit
Recommended blower : 2-45 TDC
Motor output : 22 kW
Air throughput : 5400 m³/h
Dust hose: : 2 x 8 m
Diameter : Ø150 mm
The correct height adjustment of the machine (16at the control cage and in the dust separator.
All c
must be fixed with hose clamps!
be in good condition!
inside the filter chamber.
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2-45D Operating Instructions
General
The air streams through the machine as follows:
Abrasive
Air & Dust
Fig. 3.7
Air is sucked in at the rear seal and carries along abrasive and
dust.
The air stream flows through the rebound plenum and carries along
abrasive and dust. In doing so the air stream cools the abrasive and
the housing walls.
The air enters the separator, separates the dust from the abrasive
and transports the dust to the outlet opening. The separator cover
must be closed air-tight in order to grant an optimum performance
of the separator.
The air stream then flows through the approx. 30 m long flexible
dust hose taking dust and particles with it.
The air stream now enters the filter chamber of the filter unit
where the dust and the particles are separated from the air. The
cleaned air is then fed into the environment again.
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Operating Instructions 2-45
General
3.11 Abrasive media
In order to operate the Blastrac machine 2-45D you need hardened
(max. 45 Rockwell), spherical abrasive. The machine 2-45D has been
especially designed to be operated with Blastrac abrasive.
The Blastrac abrasive is of very high quality and owns the rebouncing
ability required for the efficient use of model 2-45D. The selection of the
abrasive is very important since this is the material to carry out the
surface treatment.
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Fig. 3.8
2-45D Operating Instructions
General
Warning: never use abrasive harder than 45 Rockwell !
Otherwise the wear in the machine would increase
Selection of abrasive
Abrasive shot S460 – S550:
This abrasive shot is suitable for about 90 % of all applications. Creates
a medium to coarse profile on concrete.
Applications:
retexturing of asphalt and concrete on roads and runways
removes laitance from new concrete
roughening of smooth concrete or natural stone
removes coatings with a thickness of 1-3 mm
removes sediments on concrete prior to coating
removes flexible coatings on parking house decks
removes markings on roads and runways
disproportionately.
The effectiveness of the 2-45D depends on the rebound effect which
ensures that the abrasive can be re-used.
Please take into account that the use of incorrect abrasive increases
wear.
Our service engineers have the experience to select the appropriate
abrasive for the individual cases of application.
Please consult our local Blastrac customer service department if you
have any questions about the selection of the best abrasive for your
blast cleaning work.
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