Blastrac BMP-4000E Operating Instructions Manual
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ORIGINAL in English
OPERATING INSTRUCTIONS
BMP-4000E
BMP-4000G
VERSION 1.8

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Summary of Contents for Blastrac BMP-4000E

  • Page 1 ORIGINAL in English OPERATING INSTRUCTIONS BMP-4000E BMP-4000G VERSION 1.8...
  • Page 2: Inspection Comments

    Inspection comments Inspection before initial operation on: __________________________________________ __________________________________________ Date of initial operation: __________________________________________ Serial number & Year of manufacture: __________________________ _____________ Recurring inspections / maintenance log Date / Hour counter Findings Repairs / Cleaning Test *Competent person...
  • Page 3: Table Of Contents

    Table of contents Inspection comments 1. Introduction 2. Machine description Applications 3. Safety Work area safety Electrical safety Personal safety Machine safety Diesel version safety Maintenance safety Dust collector safety Hydraulic safety Transport safety 3.10 Signs on the machine 4. Initial operation Checkpoints of electrical safety Checkpoints of diesel engine safety Checkpoints of machine safety...
  • Page 4: Introduction

    The force of impact of a cutter is controlled by the depth adjustment. With the right depth adjustment, the best performance is obtained to give a desired result. The use of a suitable Blastrac dust collector ensures dust-free operation of the machine, clean air at the workspace and raises the life span of the machine.
  • Page 6 Operator support bracket Hydraulic milling motor Steering wheel Left Hand slide plate Electric cable guide (E-version) Exhaust diesel engine (G-version) Lifting points Diesel engine (G-version) Bonnet Oil level and temperature gauge of hydraulic oil tank Operator platform with safety switch Filler cap for hydraulic oil Dust hose connection 150mm Hydraulic oil retour filter...
  • Page 7 Diesel engine Hatz 3M41 Oil filling opening and dipstick 13 Cylinder head cover Side trim panel 14 Air filter housing cover Intake opening for combustion air 15 Lifting eye, max. load 5000 N Cooling fan belt 16 Fuel return line Cooling fan with installed three phase 17 Fuel feed line with fuel prefilter alternator...
  • Page 8 Control elements Control panel Hydraulic pressure gauge Switch for rotating beacon ON/OFF Emergency stop button (optional) Contact with key ON/OFF Worklight ON/OFF (optional) Hydraulic motor ON/OFF Water pump ON/OFF (optional) Left Hand back wheel UP/DOWN Battery charge control Right Hand back wheel UP/DOWN Engine temperature display Switch for milling motor: Oil pressure display...
  • Page 9: Safety

    3. Safety Warning! Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire, explosions and / or serious injuries. Only authorized and trained personnel may operate this machine ! This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge.
  • Page 10: Personal Safety

    The machine, specially the handle grips and operator platform must be free of fats/oils and have to be dry. All repair work has to be done by qualified Blastrac personnel, this guarantees a safe and reliable machine. g) Always use original Blastrac spare parts, cutters, sawing blades and picks. Otherwise Blastrac BV cannot guarantee the safety of the machine.
  • Page 11: Maintenance Safety

    e) To prevent fire hazards and to provide adequate ventilation, keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place flammable objects close to the engine. Anyone who is not operating this machine must be kept away from the area of operation due to a possibility of burns from hot engine components.
  • Page 12: Dust Collector Safety

    3.7 Dust collector safety a) Always use a suitable Blastrac dust cleaner to ensure a dust-free operation of the machine and clean air at the workspace. Also the airflow helps to cool the machine and prevents overheating.
  • Page 13: Transport Safety

    Be aware of your surroundings and machine operating level. Do not side hill, do not run on steep incline, this could cause machine to tip over. b) The weight of the BMP-4000E is 1550 kg without drum. Use a crane or lift when transporting the machine, use the existing lifting eyes / lugs of the machine.
  • Page 14: Signs On The Machine

    3.10 Signs on the machine The following stickers are placed on the machine. Meanings of these symbols are: ! Danger Hazardous voltage in motor Wear a dust mask class FFP3 or higher. even when solid state controller is OFF. Disconnect main power before servicing motor, controller or associated wiring.
  • Page 15: Initial Operation

    4. Initial operation Before using the machine it is of great importance to inspect the machine every day. It is not permitted to use the machine if the machine safety is not according the checkpoints below. 4.1 Checkpoints of electrical safety (E-version) Use only extension cables for extending the main cable that are sized and marked in accordance with ...
  • Page 16: Removing The Drum

    4.3 Removing the drum  Pull out the main plug before starting removing the drum.  Always wear protecting gloves and a dustmask of at least class FFP3.  Use an additional vacuum cleaner in order to work as dust free as possible. Always wear a dust mask during these operations, class FFP3 or higher.
  • Page 17: Changing Picks On The Drum

    Lift the pallet truck so the drum will be supported by the pallet truck.  Mount a rope on the two eyes which are mounted inside the drum.  Pull the drum from the axle, and support the drum.  Changing picks on the drum Lift the pallet truck up and put the drum on the drum supports.
  • Page 18: Operating

    5. Operating BMP-4000 LEFT / RIGHT CILINDER : the numbers will indicate the height of the back wheels in millimetres. (The right cylinder measuring system is optional) set “0” : these buttons are used to set the indication of the height to zero. Reset Both : pushing this button will undo the set “0”...
  • Page 19 Electric cable guide Electro box with main switch Control panel Operator platform with safety switch Dead mans switch Emergency stop button Contact with key ON/OFF Hydraulic motor ON/OFF Leveller Left Hand back wheel UP/DOWN Right Hand back wheel UP/DOWN Switch for milling motor: MILLING ON/NEUTRAL/MILLING REVERSE Switch for operating mode:...
  • Page 20: Switching The (E-Version) Machine On

    During operating the BMP-4000, the following additional safety instructions must be followed closely. Switching on the machine (E-version) Connect the machine with the power supply. (1)  Turn on the main switch (2) on the side of the machine.  Check the display (3) on the control panel, push the right button of the display, this will open the information screen -The machine won’t start if the line “Phase Seq.
  • Page 21 Symbol Meaning Battery charge control Fault in the alternator or alternator charging circuit. The battery is no longer charged. Eliminate the fault immediately. Consult the Hatz manual! Oil pressure display Switch off the engine immediately! Danger of engine damage. Check the oil level. Consult the Hatz manual! Contact Hatz service if the oil level is correct.
  • Page 22: Levelling The Machine (Without Milling)

    Procedure when faults occur  Check the indicators (21-23). After the engine comes to a standstill, the fault will continue to be displayed by the indicator for approx. another 2 minutes.  Then the electrical equipment switches off automatically.  Set the starting key to position "0".
  • Page 23: Working With The Machine

    Working with the machine Make sure the drum is off the surface and the machine is levelled.  Turn switch (13) from “Drive” to “Milling”.  Turn switch (12) to “Milling ON”  and wait for a few seconds to start up the drum Set the “Speed”...
  • Page 24: Folding In The Wheels

    Folding in the wheels Both wheels can be folded in. The right hand wheel, so the machine can be closer to the wall and the left hand wheel to change the hydraulic motor or to go through small passages. Milling is not possible when the left hand wheel is folded in. Right hand wheel: To fold in the RH wheel, lower the machine in levelled position until the drum supports on the surface.
  • Page 25: Switching Off The Diesel Engine

    Switching off the diesel engine There is a danger of injury if unauthorized persons handle the machine. Protect the starting key against unauthorized access upon breaks in operation or after completing work. Protect the ignition lock against dirt and moisture. When the starting key is pulled out, seal the ignition lock with the protective cap.
  • Page 26 Fuel Fuel type: All types of diesel fuel that meet the minimum requirements of the following specifications are suitable: ▪ EN 590 or ▪ BS 2869 A1 / A2 or ▪ ASTM D 975- 1D / 2D Winter fuel When outside temperatures drop below 0°C, use winter fuel or mix in petroleum in advance: Lowest ambient temperature Percentage of petroleum [%]for at start [°C]...
  • Page 27: Engine Oil Checking And Refilling

    Checking and refilling the engine oil Oil quality All brand name oils that satisfy at least the following specification are suitable: ▪ ACEA – B3 / E4 or better ▪ API – CF / CH-4 or better If engine oils of a low quality standard are used, the oil change interval must be reduced from 250 to 150 or from 500 to 250 operating hours depending on the engine specification.
  • Page 28 CAUTION Danger of later engine damage.  Operating the engine with an oil level below the min. mark or above the max. mark can lead to engine damage.  When checking the oil level, the engine must be horizontal and have been switched off for a few minutes.
  • Page 29: Maintenance

    6. Maintenance Please read the OWNER’S MANUAL of the diesel engine for the proper maintenance schedules. Pay attention to Chapter 3 "Safety" during maintenance and repair works. Failures due to inadequate or incorrect maintenance may generate very high repair costs and long standstill periods of the machine.
  • Page 30: Changing Coupling Buffer

    Store the cleaned and dry machine in a dry and humid free room. Protect the electrical motors from moisture, heat, dust and shocks. All repair work must to be done by qualified Blastrac personnel, this to guarantee a safe and reliable machine. Any guarantee on the machine is expired when: 19.
  • Page 31: Replacing The Shock Absorbers

    Replacing the shock absorbers The drum housing has 6 shock absorbers designed for heavy duty operation. Excessive vibrations could indicate worn out shock absorbers. The replacement interval depends on the work that has been carried out, as a rule we advise to replace them at least annually. Use the handles (1.) to let the machine down as far as possible...
  • Page 32 Slowly and carefully let the machine down. Use a pallet truck (7) and crowbar (8) to align the shock absorbers with the holes in the frame. Make sure all nuts + spring washers + washers are tightened properly.
  • Page 33: Diesel Engine Maintenance

    Diesel engine maintenance The maintenance points described in this manual are only some highlights taken from the Hatz manual. Read the OWNER’S MANUAL of the Hatz diesel engine 3M41 for the proper maintenance schedules. The maintenance plan shown below is supplied with the engine. ▪...
  • Page 34 Consult the Hatz diesel engine’s manual before performing maintenance Symbol Maintenance interval Maintenance step/check Every 8–15 operating hours or Check the oil level. every day before starting Check the intake area of the combustion air. Check the cooling air area. Every 250 operating hours Change the engine oil Check the poly v belt.
  • Page 35: Troubleshooting

    7. Troubleshooting Fault Possible cause Remedy Excessive vibration Imbalance due to worn or broken tools. Replace all worn or broken parts. or/and Unusual noises Defective bearing. Check the bearing on the axle drive shaft and replace if necessary. Check the tension of the belt, replace Wrong tension of the belt.
  • Page 36 The engine starts, but The speed control lever is not sufficiently set Set the lever to the Start position. does not continue in the Start direction. running after the starter is switched off. Indicator stays on or flashes during Stop the machine immediately and operation.
  • Page 37: Technical Data

    Engine oil consumption consumption, pertaining to (after running-in period) full load Power generator 52 KVA Design and specifications are subject to change without notice by Blastrac BV. The electrical diagrams of the electrical system are placed inside of the control panel.
  • Page 38 Vibration level: Measured; 2,15 RMS (ISO 5349) (Hand-arm vibration on steering wheel) This measure allows working continuously with the mentioned equipment without having to use anti vibration precaution measures for 10,8 hours. Measured; 0,284 RMS (ISO 2631) (Whole-body vibration on standing platform) This measure allows working continuously with the mentioned equipment without having to use anti vibration precaution measures for 24,8 hours.
  • Page 39: Storing The Machine For A Long Period

    9. Storing the machine for a lengthy period Take the following measures if you intend to take the machine out of service for a lengthy period (3-12 months): Step Activity Drain the fuel tank until it is nearly empty and fill with FAME*-free fuel. Operate the engine for a few minutes so that only FAME-free fuel is still in the fuel system.
  • Page 40 The original operating instructions are in the English language, any other language is a translation of the original version. Despite the fact that this guide is made with care, Blastrac takes no liability for errors in the manual and the possible consequences. We are naturally very interested in your findings and additions.
  • Page 41 Headquarter Blastrac Poland Blastrac Italy Blastrac The Netherlands Golina, Dworcowa 47a S.S. 10 Padana Inferiore, 41 Utrechthaven 12 PL – 63-200 Jarocin IT – 29012 Caorso (PC) NL – 3433 PN Nieuwegein Tel – 0048 627 40 41 50 Tel – 0039 0523 81 42 41 Tel –...

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Bmp-4000g

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