Operation Maintenance and Parts List For US 37455 Carbon Blaster (Audi Engines)
INSTRUCTIONS FOR OPERATING THE US 37455
CARBON BLASTER
A. ASSEMBLY AND INSTALLATION
The Carbon Blaster must be assembled as follows:
1. Straighten out discharge and return hoses; (2 and 8) to remove all kinks. Then push end of return hose (8) over the return tube at top cover of machine, making a tight secure connection.
2. Tighten the clamp (17) holding primary disposable filter bag (9) to the diffuser assembly.
3. Place secondary felt filter bag (10) in perforated basket (11) and fold top edge over. Replace cover (12) on machine.
4. Attach the 1/2" I.D. air hose (7) to the pressure regulator (4). This connection must be made air tight to prevent leakage and loss of air pressure during the blast-cleaning operation.
After the Carbon Blaster has been assembled, the intake air hose (7) may then be connected to any suitable existing air line. NOTE: Control Knob (5A) Should be in the off position before connecting to shop air. To assure efficient operation, however, the installation must conform with the following conditions:
1. The compressor must be of sufficient capacity to supply 16 C.F.M. at 60 to 80 pounds air pressure tnroughout the entire blast-cleaning operation.
2. Air line from the compressor must be 3/4" I.D. or greater, without an air line lubricator, and must be free of all obstructions. All sharp turns and reducers should be eliminated to permit free passage of air.
3. Compressor tank should be drained of all moisture. Air lines should be bled and blown clean to remove all moisture, rust, and other deposits.
4. The point at which the Carbon Blaster is connected to the air line should be within seventy-five (75) feet of the compressor itself. No other air-operated equipment of high demand should be installed between the Carbon Blaster and the Compressor.
CAUTION: To avoid static electrical shocks, ground the machine in any convenient manner.
B. PREPARATION OF MACHINE FOR USE
1. Check Filter Compartment Raise the top cover (12) of the machine and make sure that primary disposable filter bag (9) is securely attached to the cover inlet tube with clamp (17) provided. Top throat of the bag should extend far enough above the clamp (17) to assure an adequate air tight seal at this point.
Check secondary filter bag (10) in the perforated metal basket (11). Open end should lap over the edge of filter box.
NOTE: A new disposable filter bag (9) must be used each time the bag is filled. After completing each engine, inspect to see if the bag (9) is full. The secondary filter bag (10) need not be replaced, however, until the fabric has become soiled so that its filtering capacity is impaired.
CAUTION: No filter bags other than Kent-Moore should be used in the machine. These bags are designed specifically for this application providing the optimal flow characteristics which insure effective operation.
2. Fill Hopper (12) with Kent-Moore Car Blast #16 (16). To refill the machine, remove the cover and pour Kent-Moore Car Blast #16 into the hopper (12). Replace and fasten top cover securely to prevent leakage of air returned to the machine during the blastcleaning operation.
CAUTION: No cleaning agent other than Kent-Moore Car Blast #16 (16) should be used in the machine. It is a special hard-grained, non-abrasive, non-resinous material that has been prepared, graded, and sized especially for this application. Use of any other material will result in "jamming" in the machine or the engine... causing possible damage to one or both.
3. Load the Metering Chamber. Turn the "FILL-RUN" Control to the FILL position least 15 seconds. This will load the metering chamber with the correct amount of Car Blast #16 (16) to clean a single intake valve and/or combustion chamber. Thus, this step must be repeated after each blast-cleaning operation. NOTE: When the metering chamber is full a noticeable crunch of the car-blast will be felt when the control knob
(5) is returned to the run position.
CAUTION: After loading the metering chamber always make sure the Control Lever is returned to the "RUN" position. If lever is left in the "FILL" position during the blasting operation, the blast material will have a tendency to flow back into the storage compartment and thus result in a long or incomplete blast cycle.
C. ATTACHMENT OF ADAPTER(S) TO ENGINE
1. Remove intake manifold as directed by the appropriate service instructions.
2. Thread AUDI adapter nozzle (22) into end of discharge hose (2).
3. Connect discharge hose (2) to relief valve (1).
4. Select intake-valve/intake-port to be blasted and visually Inspect valve to insure it is closed.
CAUTION: Intake valve must be completely closed.
5. Install injector return hose adapter (21) into corresponding fuel injecter hole and attach return line (8) with hose clamp..
6. Attach AUDI adapter, (18 or 19) depending upon intake port configuration, with one hold down nut (20) and insert nozzle (22) through grommet of cylinder head adapter (18 or 19) and install other hold down nut (22).
CAUTION: Do not insert nozzle further than the beginning of the knurl on the nozzle when it is flush with the adapter plate.
NOTE: Use intake manifold gasket behind adapter to prevent air leaks.
WARNING: Operators of the carbon blaster should always wear safety glassses and a toxic dust respirator approved by local or state health authorities. Respirator should be used during carbon cleaning operation and when disposing of filters.
D. BLASTING
1. Make sure control knob (5) is in "RUN" position
2. Turn on air supply to blaster.
3. Hold the nozzle handle (22) and turn air control valve (5A) to the clean air position.
NOTE: Relief Valve Operation: Discharge Line Relief Valve (1):
If the flow of air within the discharge line (2)or the nozzle (22) is plugged, a loud whistling or popping sound will be heard from the discharge line relief valve (1). If this occurs, immediately turn the unit off and determine location of blockage.
4. With air flowing, adjust the pressure regulator (4) until the pressure gauge (6) reads between 60 and 80 P.S.I. Ideal operating presure is 80 P.S.I.
5. Continue to hold the nozzle handle (22) while turning the control valve (5A) to the blast position. To direct the flow of blast material to all parts of the valve, rotate the nozzle back and forth while pushing it in and out
CAUTION: DO not insert nozzle further than the beginning of the knurl on the nozzle when it is flush with the adapter plate.
NOTE: The contour of the intake valve can be felt through the nozzle. After experience has been obtained so as to properly manipulate the blast nozzle, effective cleaning may be achieved in about 60 seconds of blasting.
NOTE: Check air gauge from time to time to make sure that a constant pressure of between 60 to 80 pounds is maintained at the machine throughout the entire operation.
NOTE: The blast material flows at such a high rate of speed it is not visible in the clear discharge and return hoses. The flow of blast material can be verified by listening for a crackling sound at the middle of the hose length.
6. Blow out the loose material as follows:
After completing the "blast-cycle" turn the Air Control Valve (5A) back to the "CLEAN" position again. With valve in this position, air passes through top of metering chamber without picking up blast material. Then, with only compressed air entering the chamber, turn the nozzle slowly as before to scavenge all parts of the intake port and remove all loose carbon particles and blast material.
7. Return Air Control Valve (SA) back to the "Off" positon.
NOTE: Refill metering Chamber as indicated in step B3 and continue on to the next intake valve/intake-port to be blasted.