important safety instructions

1
WARNING!
DO not use a Pressure Blaster until you have read this manual and you
understand its contents and warnings. These warnings are included for
the health and safety of the operator and those in the immediate vicinity.
Keep this manual for future reference.
Dust created by power sanding, sawing, grinding, drilling, and other
construction activities may contain chemicals known to cause cancer, birth
defects or other reproductive harm and respiratory illnesses. Some
examples of the chemicals include:
· Lead from lead based paints
· Crystalline silica from bricks, cement and other masonry products
· Arsenic and chromium from chemically-treated lumber
Your risk from these exposures varies, depending on how often you do this type
of work. To reduce your exposure to these chemicals: Work in a
ventilated area, and work with approved safety equipment, such as those
dust masks that are specially designed to filter out microscopic particles.
Abrasive blasting produces harmful dust. Everyone in the blasting area
must wear a properly fitted and properly maintained NIOSH-approved
supplied-air respirator.
SILICOSIS AND OTHER DUST WARNINGS:
Breathing dust from silica sand may cause silicosis, a fatal lung disease.
Breathing dust during blasting operations may also cause asbestosis
and/or other serious or fatal diseases. A NIOSH-approved, well-maintained
air-supplied abrasive blasting respirator must be used by anyone blasting,
anyone handling or using media containing toxic substances or media with
more than point one percent free crystalline silica and anyone in the area of the
dust, Harmful dust can remain suspended in the air for long periods of time
after blasting has ceased, causing serious injury or death.
Before removing respirator, use an air monitoring instrument to determine
if atmosphere is safe to breathe. Contact local OHSA or NIOSH office to
determine the proper respirator for your particular application.
Supplied-Air respirators do not remove or protect against carbon monoxide
If atmosphere is safe to breathe. Contact local OHSA or NIOSH office to
Determine the proper respirator for your particular application.
Supplied-Air respirators do not remove or protect against carbon monoxide
(CO) or any other toxic gas, Use a carbon monoxide removal device and
Monitoring device with the respirator to ensure grade D quality air. Follow
All applicable OSHA standards and OSHA regulation 1910.134(d).
2
SPECIFICATIONS
Tank Volume
Hose Length:
Working Pressure
Air Consumption:
Overall Dimensions:
Weight:
5 gallon
8 feet
60-110 PSI
6-25cfm
13-3/8”×15-3/4”×30-25/32”
27 lbs
SAVE THESE INSTRUCTIONS
You will need these instructions for the safety instructions, the operating
procedures, the parts list and the warranty. Put them in a safe and dry place for
future reference.
IMPORTANT SAFETY INSTRUCTIONS
WARNING: When using tools such as your air compressor, whether powered by
electric motor or gasoline engine, basic safety precautions should always be
followed to reduce the risk of fire, electric shock, and personal injury.
You should review the safety instructions for your air compressor before
beginning abrasive blasting with this tool.
3
PRESSURE BLASTER SAFETY PROCEDURES
CAUTION: READ THESE SAFETY PROCEDURES IN THEIR ENTIRETY-PARTS OF THE OPERATING INSTRUCTIONS ARE WITHIN THESE WARNINGS.
These procedures are not intended to be exhaustive due to the many variables
in the abrasive blasting field. Therefore, we INSIST that the hands, ears, mouth,
nose and eyes be covered with appropriate safety protection at all times.
ADDITIONAL WARNINGS!
CAUTION MUST BE EXERCISED BY USER AT ALL TIMES
1.
Do not place fingers, any body parts or any components in the filler
plug seal area when the blast machine is being pressurized. Failure
to keep body parts from the filler plug area will result in serious injury.
2.
Do not exceed maximum working pressure of 110 PSI. Failure to keep
maximum working pressure below 125PSI can cause the blast machine
to burst, causing death or serious injury.
3.
Everyone in the blast area including the equipment operator should
correctly use and maintain a NIOSH-approved air-supplied respirator,
even after blasting has ceased. Harmful dust can remain suspended in
the air for long periods of time after blasting has ceased causing
injury or death.
4.
Before using the pressure blaster: Put on safety glasses, gloves, and
NIOSH-approved respirator. Always wear these protective items
when operating and while servicing your abrasive blaster. While a
protective hood is provided to help protect you from flying particles
as you use the machine, the hood does not provide protection from
air borne particles. A well maintained air supplied blasting respirator
must be used by anyone blasting.
5.
Use thick gloves with gauntlets to protect your hands.
6.
Use backboards to prevent overspray from hitting someone or
something else because the dust will travel a long distance. Blast in
a large open area to minimize abrasive accumulation in surrounding areas.
7.
Do not pull media tank around by the abrasive hose or let tank fall over as
a fitting may break rendering the machine unsafe. Media and air under 110
PSI has a very high destructive force. Never leave a pressurized machine
unattended. If an emergency occurs, such as a burst blast hose, shutdown
the machine immediately.
8.
Drain air out of tank through the inlet valve and disconnect power before
maintenance cleaning of any kind. When removing nozzle, caution must be
exercised as air pressure may still be in the hose if the nozzle is plugged.
4
9.
For safe operation, perform recommended preventive maintenance on
blaster tank, remote unit and accessories. Replace all worn parts before
they fail. Immediate replacement of worn components is required. Failure
to replace worn components could result in exposing the operator or
bystanders to high speed media and compressed air, causing serious
injury.
10.
Do not use corrosive materials of any type in unit. Use only clean, dry
media.
11.
Do not splice abrasive hose. The splice will wear out quickly and
may violently spray media over the surrounding area. A worn blast
hose could suddenly fail by bursting, Couplings and nozzle holders
may not adequately grip worn hose, causing them to blow off
under pressure. Compressed air and abrasive escaping from a burst
hose,
or disconnected coupling or nozzle holder could cause severe injury.
12.
Welding, grinding, or drilling on the blast machine could weaken the
vessel. Compressed air pressure could cause a weakened blast
machine to rupture, resulting in death or serious injury.
13.
Always place the machine so that the outlet is pointed away from any
objects or persons. Stand clear of the path of exiting abrasive. It
may come out at high velocity. Impact from exiting abrasive could
cause severe injury.
14.
Static electricity can be created by the use of this equipment. Do not
Use within fifty feet of any explosive, potentially explosive
Substances, or their vapors as an explosion can occur.
15.
Do not use this equipment in any area that might be considered
hazardous or where flammable gases or liquids are present. Failure
to do so may cause an explosion resulting in serious injury.
16.
Do not overfill tank with media. Do not fill to within 6 inches from top
of the tank.
17.
BEFORE OPENING THE TANK, release the air pressure on the
abrasive tank. To do this, turn off the air supply valve (31), and push
down to open the DEADMAN valve (25), to release pressure in the
line. Ensure that the tank pressure gauge (9) reads zero, then open
the tank.
18.
MAINTAIN CORRECT AIR PRESSURE, maximum of 110 PSI is
recommended, pressure must not exceed 125 PSI. If pressure
exceeds 125 PSI, stop all work immediately, and disconnect the air
compressor to reduce the excess pressure. Do not investigate the
blaster’s pressure problem until the pressure gauge (9), reads zero.
5
ASSEMBING THE ABRASIVE BLASTER
1.
Refer to the drawing for step 1, assembling the intake manifold (12).
First, attach the pressure gauge (9), to the top of the intake
manifold, turning the gauge so that is can be see across the top of
the tank. Next, attach the throttling valve (31) to the bottom of the
manifold. Attach the nipple connector, to the throttling valve.
Attach the joint pipe (10), to the manifold.
2.
Refer to the drawing for step 2, to assemble the water trap filter (9).
nipple connector (11) is screwed into each side of the filter. On
one side, attach the air supply valve (31), to the nipple connector (10),
and then attach the male/female connector (8), to the other
side of the air supply valve. When you’re ready to operate the
abrasive blaster, the air hose from the compressor will fasten to the
male/female connector (8).
3.
Place the tank (15) on a table with the four clips up. Refer to the
drawing for step 3. Screw the water trap filter (9) and its parts into
the hole at the side of the intake manifold. Then screw the open end
of the joint pipe (10) with intake manifold (12) and pressure gauge
(9) attached into the threaded hole on the side of the filler pipe on
Top of the tank. Again, be sure that the manifold and gauge are vertical.
4.
Refer to the drawing for step 4, assembly of the abrasive outlet valve
into the hole at the bottom of the tank; Attach four parts, in order:
Nipple connector (11); abrasive metering valve (30); nipple
Connector (11) and the abrasive outlet pipe (12).
5.
Refer to the drawing for step 5, assembly of the nozzle DEADMAN
valve (25). In this assembly process, you’ll select one of the four
nozzles (27). This is not a permanent selection, as you may change
nozzles according to the job being done. Screw the adapter (23), into
the nozzle DEADMAN valve (25). Screw the gasket (26) into the nipple
connector, then add a nozzle (27) and the nozzle cap-nut (28).
6.
Refer to the drawing for step 6, for connecting the abrasive metering
valve assembly and the assembly.
Slide the two hose clamps (22), over each end of the abrasive hose (21),
press one end of the hose, over the nipple on the abrasive outlet
pipe (12) and the other end over the adapter (23). Both hose
ends should be firmly seated on the nipples. Slide the hose clamps
along the hose to each nipple and tighten the clamps very firmly.
7.
Fasten the two handlebars (06) to the tank using four pan screws (02)
and four washers and four hex nuts. Note: keep the handle curve
ends upward.
8.
Locate the axle (29), and slide it through the holes in the sides of the
handlebars (06). Place one wheel (16) at each end of the axle and
fasten then into place with cotter pins (14) and washer (34).
9.
Insert the fixed foot (17)onto the fitting on the bottom of the tank
near the edge. Use your last cotter pin (14) to hold the foot to the
tank.
10. Before beginning operations, go back over each connection, double
checking to ensure that all are tight and properly seated.
6
MAINTENANCE
WARNING!
Failure to observe the following before performing any maintenance could
cause serious injury or death from the sudden release of compressed air:
·
·
·
·
Depressurize the blast machine.
Disconnect power supply.
Lockout and tag out the compressed air supply.
Bleed the air supply line to the blast gun.
Immediate replacement of worn components is required. Failure to replace
worn components could expose the operator or bystanders to high speed
media and compressed air could cause death or serious injury.
Leaks around couplings and nozzle holders indicate worn or loose fitting
parts. Nozzle holders and couplings that do not fit tightly on hose and
nozzles that do not fit tightly in nozzle holders could disconnect while
under pressure. Impact from nozzles, couplings, hoses, or abrasive, and
parts disconnected while under pressure could cause severe injury.
To ensure a long and efficient operational life of the Deadman Handle, it is
highly recommended that the following procedures be followed:
1.
Periodically(after 5-6 months of moderato use or after 10-15 hours of
heavy industrial use) replace all hose adaptors that are for abrasive flow
use only.
2.
Periodically replace sealing block in deadman handle to maintain proper
shut-off.
3.
Replace abrasive hose when it begins to soften or leaks media or air
around the hose or handle area.
4.
Replace the nozzle when it wears to the next larger size.
5.
Adjustment of sealing block may be required after nozzle change.
7
OTHER MAINTENANCE ITEMS:
1.
You should make every effort to protect your air compressor from any
damage it may receive from your abrasive blasting work. Your best option
is to keep the compressor up wind from the abrasive blasting, and the
greater the distance between them, the better. Other than that, you should
continue standard maintenance procedures for the compressor.
2.
Some parts of the abrasive blaster will wear much more rapidly than
others, the parts needing close attention carry the air/abrasive mixture,
starting with the abrasive hose (21) and going through the metal fillings,
the DEADMAN valve (25) and the ceramic nozzles (27).
3.
If air leaks develop in any of these parts, you should stop all work ,and find
what needs to be repaired or replaced. When it’s new, the abrasive hose
(21) has 2 cord piles and the walls are 1/4” thick. As the interior diameter is
abraded, this wall becomes thinner and thinner. One way to inspect the
hose and other parts affected by the blasting is to put on your protective
clothing. Then pressurize the system and close the nozzle shut off the
valve (31). Listen for air leaks, fix any leaks before operating. You can
also spot places in the hose where the wall is getting very thin. These
show up as blisters in the hose; if you find such a blister, get a new hose
immediately. If that blister breaks, the abrasive will come out of the side of
the hose.
8
AIR COMPRESSOR RECOMMENDATION:
To permit efficient operation of your air compressor, follow these guidelines:
1.
Use a smaller size nozzle to control the demand of air.
2.
Do not blast continuously. Stop blasting operation periodically to allow the
compressor to cool. No compressor is designed to constantly run at full
RPM. Use 70% of the rated output.
3.
Use a minimum 1/2” air hose or metal piping from your air compressor to
the blaster. If you compressor is creating an excessive amount of
moisture, we recommend using a water trap or a moisture separator.
4.
The air compressor should be drained at the bottom of the supply tank
through a drain valve and should be blown down daily. It is not unusual to
drain three or four gallons of water from the supply tank on a high humidity
day. An additional supply tank will help.
5.
Keep dust and media created by blasting away from the air compressor
unit. Observe maximum air pressure requirements for the blaster and
either set your compressor to run within these limits or use a pressure
regulator valve to reduce the air pressure to the appropriate range.
ABRASIVE (MEDIA) USAGE:
1.
If moisture is in the media it will eventually damage the blaster tank or
plug the system. Keep the media and compressor air dry to avoid this
problem.
2.
If media is moist, screen it and dry it before using.
3.
Do not leave media in the tank after blasting because it can absorb
moisture and impair blasting performance.
4.
Store media in a dry place; keep media off the ground or concrete floors
Put it on a wooden skid.
5.
If the humidity is excessively high, it may not be advisable to blast at that
time.
6.
Consider using different grades or different types of media to prevent
nozzle clogging due to high moisture content.
7.
DO not use sand.
9
OPERATING INSTRUCTIONS
OPERATING TECHNIQUE:
1.
Connect air hose to air inlet valve. Manufacturer recommends using
minimum incoming air hose of 1/2” I.D. using an air hose smaller than
1/2” I.D. will restrict air volume and result in poor unit operation. Prior to
Injection of air, be certain air inlet valve and nozzle valve are in the OFF
position. With Deadman Valve closed and filler plug tight, open air inlet
valve allowing air to pressurize. Operating range of unit is 40 to 110 PSI
Note: For proper nozzle selection, refer to nozzle selection chart on page
11. after proper nozzle selection, insert nozzle into retainer base. Set
against washer and slide retainer nut over nozzle and tighten by hand.
2.
Manufacturer recommends a fine grade abrasive with granular size
similar to that of table salt. This assures proper flow and reduces the
possibility of nozzle obstruction.
3.
With the blaster pressurized and abrasive flow regulator valve at base of
unit closed, open ball valve allowing air to flow through by-pass hose to
base of the unit. Then holding the abrasive hose by nozzle retainer
housing with nozzle directed away from unit and operator, quickly
squeeze the Deadman Valve fully open and adjust the regulator valve at
base of tank to bleed the abrasive into air flow. Slowly open regulator
valve until abrasive material is slightly visible. Once the regulator flow
valve is adjusted to the desired setting, further adjustment should only
be required when changing grade of abrasive material or when a nozzle
with a different I.D. is used. Opening regulator valve too far will result in
a clogged hose or nozzle.
For best performance, the Deadman Valve should be opened and closed quickly
WARNING!
Disconnecting hose while Unit is under pressure could cause serious injury or
death. Use safety lock pins and safety cables in all coupling connections to
help prevent hose couplings from accidental disconnection.
If twist-on type air hose couplings are used, they must be secured by
safety lock pins or wires to prevent accidental disconnection while under
pressure. Hose disconnection while under pressure could cause serious injury.
10
Warning! Do not fill the pressure vessel to within six (6) inches of the top of
the vessel. If a hose is accidentally disconnected during use media spray
may occur.
See respiratory related WARNINGS at the beginning of the manual.
Coal Slag
Coal Slag is used when paint and rust has to be removed from steel, such as
Car bodies, tanks or heavy machinery. Coal Slag is superior to silica because
It only has 0.1% free silica, is faster cutting, can be re-used, is moisture free, and
will not pack or absorb moisture.
Steel Grit
Steel grit is extremely fast cutting on rusty metal and hard to remove paint. Steel
Grit is popular because it leaves a very smooth finish. It is also comparable in
Price to most other specialty abrasives. Steel Grit is recommended in reclaim
Systems or cabinets.
Glass Bead
Glass Bead is used in creating a satin or matte finish. Glass Bead is
recommended in reclaim systems or cabinets.
Aluminum Oxide
Aluminum Oxide is a high quality abrasive that is sharper than sand (not
recommended) and cuts twice as fast as sand. It leaves a smooth textured finish
with no pits. Aluminum Oxide is rougher than glass bead and can be
used over and over again. It is one of the most economical abrasives you can
use in any reclaim systems or cabinets.
Plastic Grit
Primarily used to strip aluminum and fiberglass. Great for stripping paint. Light
oxidation and surface rust. Recommended for use is blast cabinets because it
creates very little dust. Works quickly, last a long time and increases visibility
within the cabinet.
11
AIR ABRASIVE SUPPLY REQUIREMENTS
Abrasive blasting requires a large volume of air at high pressure. The efficiency
of your abrasive blaster can be adversely affected by the use of too small an air
supply hose, insufficient air pressure or an overly large nozzle.
Hose ID
Hose Length
Nozzle ID
3/8”
3/8”
1/2”
1/2”
50ft
25ft
50ft
25ft
3/32”
7/64”
1/8”
9/64”
CFM@
PSI
6
12
15
20
110 Abrasive Use
Per Hour
60 lbs
100 lbs
150 lbs
200 lbs
We recommend that air pressure in the range of 65/110 PSI will provide the best
Results.
LOADING ABRASIVES INTO THE TANK
1.
Check your abrasive to be sure it’s dry, and won’t clog the metering valve
(30), abrasive outlet pipe (12), hose (21), or other components.
2.
Put on the protective clothing, full hood and MSHA/NICOSH approved
Respirator.
3.
Turn the air supply valve (31) to the off (horizontal) position.
4.
Push down to open the nozzle DEADMAN valve (25).
5.
Watch the pressure gauge (9) and make sure it reads zero pressure.
6.
Remove the filler cap (4) from the top of the tank.
7.
Insert the funnel (19), and pour the abrasive into the funnel. Be sure to get
enough into the tank to do the job at hand. But if this is a big job, fill the
tank only 3/4 full, and reload as needed to finish the work.
TIP: if the humidity is 90/100%, the water trap (9) won’t be able to trap all of the
moisture in a 3/4 tank. Better to reduce the amount of abrasive, load more
frequently, and empty the water trap more open. This will reduce the possibility of
clogging the bottom of the tank or the line.
8. with the correct amount of abrasive in the tank, close the filler cap (4).
12
9.
Close the nozzle shut-off valve (30), and open the air supply valve (31).
10.
Listen for air leaks at the filler cap as you begin to pressurize the tank from
the compressor. Fix any leaks before operating.
13
Drawing for steps beginning with step number one.
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