OPERATOR S INSTRUCTION MANUAL

Aussie Eco-Clean Hydraulic Drive High Pressure Blaster Sept 2014 OPERATOR S INSTRUCTION MANUAL Models: TTL 1330 HYD TTK 2130 HYD RAL 2035 HYD Hydraulic specialist to install Note: Max pump rpm 1450 Operators must read this manual and understand it before operating this machine Australian Pump Industries www.aussiepumps.com.au Hydraulic drive blasters to 500 BAR (7,200 psi) coming soon REF: APHYDHPBVER1

AUSSIE HIGH PRESSURE BLASTER RISK ASSESSMENT MODELS: In line with the National Occupation Health & Safety Commission s requirements the data below applies to the Aussie range of high pressure water blaster models: TTL1330 HYD (Class A) TTK 2130 HYD (Class B) RAL 2035 HYD (Class B) DESCRIPTION: Hydraulic drive high pressure cold water blasters designed for professional cleaning applications. MATERIAL CONSTRUCTION: Aussie hydraulic drive pressure washers are designed to be mounted to a vehicle or plant with access to a hydraulic drive system. They consist of a triplex style three piston high pressure pump. RISK RANKING METHOD: Risk is the combination of the likelihood of a specific unwanted event and the potential consequences if it should occur. RISK RANKING METHOD: For each event, the appropriate probability (a letter A to E) and consequences (a number 1 to 5) is selected. PROBABILITIES: A. Common or repeating occurrence. B. Known to occur or it has happened. C. Could occur, or I ve heard of it happening. D. Not likely to occur. E. Practically impossible. CONSEQUENCES FOR PEOPLE: 1. Fatality or permanent disability. 2. Serious lost time, injury or illness. 3. Moderate lost time, injury or illness. 4. Minor lost time, injury or illness. 5. No lost time. RISK RANKING TABLE: The consequences (loss outcomes) are combined with the probability (of those outcomes) in the risk ranking table to identify the risk rank of each loss event (e.g. a consequence of 3 with a probability of B yields a risk rank of 9). The table yields a risk rank from 1 to 25 for each set of probabilities and consequences. A rank of 1 is the highest magnitude or risk that is a highly likely, very serious event. A rank of 25 represents the lowest magnitude of risk, an almost impossible very low consequence event. Controls must be taken to either eliminate or minimise the risk. C O N S E Q U E N C E PROBABILITY A B C D E 1 1 2 4 7 11 2 3 5 8 12 16 3 6 9 13 17 20 4 10 14 18 21 23 5 15 19 22 24 25 2 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

POTENTIAL HAZARD: Hazard Yes/ No Risk Risk Rating Controls Entanglement with hose (tripping, falling) Yes Personal injury of the operator or bystanders 13 Warning stickers hose reel option Injury from high pressure water Yes Personal injury of the operator or bystanders 13 Warning notice on blaster Warning in Operator s Manual, Use of safety protection clothing (Aussie Pro-operator) Use of barriers to keep bystanders away from work area High temperature (from engine muffler and other components) Yes Burns from muffler 15 Warning sticker on machine Noise Yes Hearing damage 15 Warning sticker regarding ear muffs to be used during operation Dislodged particles in atmosphere Yes Sight damage 6 Warning regarding wearing safety glasses. Slipping on wet surface Yes Personal injury 9 Use of proper footwear Contact with chemical cleaners used to clean surfaces Yes Skin contact could result in burns, skin irritation etc. Fumes from some chemicals may lead to respiratory problems 4 Chemical cleaners to only be used as a last resort when other methods have failed. Areas to be kept well ventilated. Staff to follow manufacturers instructions at all times for use, storage & disposal. Staff to wear the appropriate PPE Respiratory protection when required Signed originator... Job title... Date Completed... Refer to Work Safe Australia Guide for Managing Risks from High Pressure Water Jetting 2013 for information regarding Class A & Class B machines. Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 3

CONTENTS Risk Assessment... 2 System Specifications... 4 Guarantee... 5 Standard Equipment... 5 Installation of Hydraulic Motor... 5 Initial Set Up of Hydraulic Blaster... 6 Safety Precautions... 7 Assembly & Preparation for Use... 8 High Pressure Hose... 8 Water Supply Hose... 9 Operation... 10 Accessories... 10 Care & Maintenance... 11 ASP System... 11 Trouble Shooting Guide... 12 Parts Identification... 13 Pump Breakdowns... 14 Maintenance Checklists... 16 * * W A R N I N G * * AUSSIE HEAVY DUTY WATER BLASTERS ARE DESIGNED FOR PROFESSIONAL OPERATORS ONLY SYSTEM SPECIFICATIONS Model Stock Code Pump Pressure (psi) EWP (psi) Flow rate (lpm) Hydraulic motor Hydraulic pressure required (psi) Hydraulic flow required (lpm) Pump rpm Machine class TTL1330/HYD BTTL1330/HYDKIT 4,300 7,000 13 Casappa PLM 30 22 2900 38.5 1450 Class A TTK2130/HYD BTTK2130/HYDKIT 4,300 7,000 21 Casappa PLM 30 34 2900 60 1450 Class B RAL2035/HYD BRAL2035/HYDKIT 5,075 8,500 20 Casappa PLM 30 38 3045 68 1450 Class B Do not over-speed the pump your hydraulic specialist must limit flow to motor when installing unit. Before attempting to operate your machine please read this Instruction Manual thoroughly following all directions carefully. By doing so you will ensure safe operation of the unit and will enjoy long and trouble free service from your heavy duty water blaster. 4 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

AUSSIE ECO CLEAN HYDRAULIC DRIVE BLASTER OPERATING & MAINTENANCE INSTRUCTIONS GUARANTEE This Aussie Eco Clean product is guaranteed against faults in manufacture for one year from purchase. The Bertolini pump has a three year warranty, but must be serviced by an authorised service agent every six months to maintain this warranty. Keep your receipt as proof of purchase and all service receipts. This guarantee is invalid if the product is found to have been abused in any way, or not used for the purpose for which it was intended. Routine maintenance is the owner s responsibility. Failure to maintain the machine in line with the services outlined on the back page will invalidate warranty. High pressure accessories carry a 3 month warranty. Where possible return faulty goods to the place of purchase. No products can be returned to us without our prior permission. The reason for return must be clearly state. N.B. Warranty is not transferrable to third parties in the event of sale of the machine within the warranty period. Please note that any parts used in warranty repairs are guaranteed for a period limited by the original warranty of the parent product. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits under the Aussie Pump warranty are in addition to other rights under Australian Consumer Law. Hydraulic drive warranty is the responsibility of the hydraulic drive unit manufacturer. The unit must be returned to authorised dealer for evaluation of warranty. STANDARD EQUIPMENT Before proceeding with assembly of your new Aussie Eco Clean blaster, check that all parts listed below are included. 1 Gun handle assembly & quick coupler assembly 1 Lance & nozzle assembly 1 high pressure hose assembly 1 Inlet brass hose tail & clamp INSTALLATION OF HYDRAULIC MOTOR Refer to Casappa Polaris manual for full installation instructions. Please consult a hydraulic engineer and ensure system includes limiting devices to prevent piston pump from overspeeding (Max pump rpm 1450). Failure to connect hydraulic drive correctly can result in damage to hydraulic motor and piston pump. Damage caused by incorrect installation is not covered under warranty. Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 5

INITIAL SET UP OF HYDRAULIC BLASTER (TO BE COMPLETED ONCE HYDRAULIC MOTOR IS OPERATIONAL) The Aussie Eco-clean blaster is powered by a Casappa hydraulic motor. NOTE: The hydraulic system must be designed to include devices to limit the flow and pressure of the system within the limits of the motor. Failure to do so will cause damage to the piston pump by over speeding and void warranty for the unit. (Max pump rpm 1450). E D A B C The following steps should be taken to set the unloader and safety valve with the unit running. 1. Before setting the pressure, the lock nut (C) on the safety valve (VS240) should be undone and the hex bolt (D), should be screwed at least 3/4 in. 2. The lock nut on the unloader (A) should be undone and the adjusting nut (b), should be screwed in gradually until the required pressure is obtained (see pump specifications on page 4) whilst the trigger is pulled and water is running through the pump. The lock nut (A) should then be secured in place and a paint mark added across the two nuts for security. 3. With the pump running at the required pressure, the hex bolt (D) on the safety valve should be adjusted out until there is a slight drip and then screwed in one quarter of a turn, this will set the safety valve 10% over the required pressure. The lock nut (C) should then be locked off. The water drip should stop. If not adjust another 1/4 turn. 4. The unit is by-passing correctly when pressure on the gauge is reading the required pressure with trigger pulled and zero (0) psi when trigger is released. The pump is fitted with 1 metre of open end by-pass hose (E). This would normally be attached to the water supply tank. When the unit is in by-pass mode (trigger closed on the gun), full pump water flow will be sent through this hose. By-pass can be sent back to pump if required. (contact your Aussie Pump service agent for details). Blocking or plugging the by-pass hose will void warranty and blow the pump seals. 6 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

SAFETY PRECAUTIONS - IMPORTANT 1. NEVER direct the spray jet at any person or animal. 2. NEVER direct spray jet at any surface that may contain asbestos material. 3. NEVER hold a finger over the high pressure nozzle. 4. NEVER direct the spray jet at the machine itself or any electrical equipment. 5. After use release the pressure in the high pressure hose by operating the pistol trigger. 6. DO NOT attempt any mechanical repair. If you have a problem with your machine contact your local Aussie Eco Clean Service Division, phone (02) 8865 3500. 7. NEVER supply any liquid other than water to the water inlet. 8. NEVER pull the high pressure hose if it has formed kinks or nooses. 9. NEVER pull the hose over sharp objects. 10. DO NOT attempt to disconnect any hose or coupling with pressure still in the hose. 11. DO NOT operate the machine whilst standing on ladders, use a platform tower or scaffolding. 12. Children should NOT be allowed to use the machine. 13. We recommend the use of safety goggles when using the machine, particularly with the sand blasting attachment (optional accessory) or any application where loose particles of stone or grit, etc. may be blown around by the pressure spray. Aussie Safe Operator Essential operator protection to 500 BAR (Check Aussie Blaster Blitz for more information) STAY SAFE Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 7

ASSEMBLY AND PREPARATION FOR USE If pressure drops off, check nozzle for wear. Nozzles should be replaced on a regular basis (every month for machines in regular use, every 3 months for machines used intermittently. Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be dangerous to the operator. 1. Check the oil in the pump. With the machine on a level surface the oil level should cover the red dot in the oil level sight glass on the side of the machine. If necessary, top up with SAE 30w 50 oil (non foaming type). Do not mix different grades of oil as this may affect the machines performance. If alternative oil is used, first empty out oil by unscrewing drain plug in bottom of machine. 2. Ensure breather plug is fitted to pump (red/black) WARNING: Before operation ensure top mounted oil filler plug is replaced by breather. Failure to fit breather and keep clean can result in over pressuring of oil chamber (crank case) and can blow oil seals. This will void warranty. 3. Check hydraulic fluid level. Refer to hydraulic drive hand book. HEAVY DUTY LANCE: To assemble insert lance into gun and check nozzle has been fitted to other end of lance HIGH PRESSURE HOSE Connect the high pressure hose to the threaded water outlet on the side of the machine via a screw coupling. No spanners are necessary. High pressure hose connection Supply hose (insert brass hose tail first) 8 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

WATER SUPPLY HOSE: Use a good quality supply hose (not supplied) of 19mm diameter minimum on TTL & TTK versions, 25mm on RAL version. Fasten the one end of the hose to the inlet hose connector securing using a worm drive clamp. This connection MUST be tight to avoid leaks. (19mm hose tail provided TTL & TTK versions, 25mm hose tail on RAL version. ) Water supply can be by means of either: $ Mains Supply Secure the free end of the hose to your tap using a suitable tap adaptor (not supplied - available through all good hardware and garden supply stores). $ Syphon Fed Supply Place the free end of the hose into a water tank or container and the pump will draw water itself. Use a larger diameter suction hose, at least 3/4" diameter and no more than 2 metres long. Water supply must be above or level with pump. NOTE: The unit is fitted with a Y strainer inlet filter. Ensure this is removed and rinsed to clear debris before each use. OPERATION: Turn on water supply if applicable. Note: Tap should be full on. Pull the trigger to expel air from the system. Water will trickle from the end of the lance when air is expelled. Engage hydraulic to power to blaster. Check that there are no leaks in the line connections, gun or power lance. Pressure begins when the pistol trigger is squeezed. SHUT DOWN Turn off water supply if applicable. Disengage hydraulic to power to blaster. Pull the trigger release pressure from the system. Gun trigger should be locked to prevent accidental activation. Hose and gun/lance assembly can now be stowed or detached. NOTE: Failure to release pressure before disconnecting the hose quick coupler will result in the quick coupler o-ring seal blowing out. This o-ring must be replaced before operating machine. Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 9

ACCESSORIES: (CONSULT AUSSIE BLASTER BLITZ FOR DETAILS) Your Aussie water blaster can be used with a wide variety of optional extras to enhance performance. To use the accessories you must first disassemble the lance. Unscrew quick coupler to unlock the lance. The accessories can then be connected to the end of the lance assembly. If quick coupler is not supplied it can be purchased from your local Aussie Eco-Clean Distributor. TURBO LANCE - A correctly selected heavy duty turbo lance can cut pressure cleaning time in half and is a very important accessory. SANDBLAST HEAD - Wet grit-blasting is safe and tremendously effective. Ideal for rust removal, paint stripping and graffiti removal. OPTIONAL LANCES - A range of optional lances in stainless steel or zinc plated steel are available in lengths of up to 2 metres. ROTARY CLEANER - The Aussie Eco-Clean rotary cleaner allows flat surfaces to be cleaned in a fraction of the time normally taken. Ideal for contractors and professional users. LONG LENGTH HOSES - HOSE REELS, COUPLINGS - A wide range of optional long length hose assemblies, rapid reel hose reels and quick couplers and fittings are available to enhance your machine=s performance. Consult your Aussie Eco-Clean Distributor for details. Personal protection apparel recommended. Aussie Safe Operator Essential operator protection to 500 BAR (Check Aussie Blaster Blitz for more information) STAY SAFE 10 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

CARE AND MAINTENANCE: AFTER EACH USE... If cleaning agents have been mixed with the incoming water, it is particularly important to flush the machine with clean water after use. If there is a danger of freezing anti-freeze should be mixed with the flush water or the machine must be completely drained. After the final flush stop the machine. DO NOT allow the machine to idle for more than 15 seconds. This is particularly important when there is a danger of freezing. Do not run for longer without water supply. ASP SYSTEM... AUSSIE SAFETY PROTECTOR SYSTEM AUSSIE SAFETY VALVE (B): This device blows off excess pressure if unloader has been tampered with thus protecting the pump. Do not tamper with pre-set unloader (A) and safety valve. (This will void your warranty.) B A Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 11

TROUBLE SHOOTING GUIDE FAULT CAUSE REMEDY Pump running normally but pressure low on installation Fluctuating Pressure Pressure low after period of normal use Pump Noisy Presence of water in oil Water dripping below pump Oil Dripping Valves switches repeatedly when gun is off Pump sucking air Valves sticking Unloader valve seat faulty Nozzle incorrectly sized Worn piston packing Valves worn Valves blocked Pump sucking air Worn piston packing Nozzle worn Check valves worn Check valves blocked Unloader valve seat worn Worn piston packing Cracked pistons from dry running Air in suction Broken or weak suction or delivery valve spring Foreign matter in valves Worn bearing Excessive temperature of liquid Oil seal worn High humidity in air Piston packing worn Piston packing worn O.R plunger retainer worn Travel plug in use on pump Oil seal worn Leaking gun and/or pressure pipe. Leaky sleeve Worn out kick-back valve body Leaky seals Check water supply and possibility of air ingress. Check and clean or replace if necessary Check water supply and air ingress at joints in suction line Check and clean Replace pistons Check water supply and connections on suction line Check and clean Reduce temperature Check and change oil twice as often Replace with breather plug if necessary Renew gun, seal pressure pipe Renew sleeve Check and renew as necessary kick-back valve plate and seat Renew seals Leaky piston rod Defective O-Ring/Support Ring Renew piston rod seals and examine surfaces in guide case Leaky by-pass at nominal pressure Nozzle too small, too much water. Worn out by-pass valve Install larger nozzle Examine and renew as necessary Pressure gauge shows high pressure fluctuations when shutting off gun Valve set too high above operating pressure Dirty valve Adjust the unloader at the operating pressure. Clean valve (removing lime deposits etc). Grease parts before installing. Back pressure in supply hose when gun shut off Dirty or worn low pressure valves Clean or replace valves 12 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

PARTS IDENTIFICATION F L J K H I Position Part No Description TTL 1330 TTK 2130 RAL 2035 Nozzles C915035M HP NOZZLE (15 ANGLE, TIP SIZE 035) x C915045M HP NOZZLE (15 ANGLE, TIP SIZE 045) x C915055M HP NOZZLE (15 ANGLE, TIP SIZE 055) x Lance C3905.15 900MM SS DOUBLE LANCE C/W BOOT x x MPA40026100 S3-350 LANCE x Gun CGPDG5010 5,000 PSI GUN x x x Hose AR206K2214X2X10 10 MTR HP HOSE (R2, 4500 PSI) x x AHW06FB6FB6X10 10 MTR HP HOSE (R2, 5,800 PSI) x Unloader F BVB350 UNLOADER VALVE (5100 PSI) x x x Safety Valves H MPA60156000 4000 PSI SAFETY VALVE x x MPA60058000 VS350 SAFETY VALVE (5100 PSI) x Strainer I AYSTRAINER3/4 STRAINER 3/4 x x x Gauge J AGCDR0102 6000 PSI GAUGE x x x Hydraulic motor PLM30 22 CASAPPA MOTOR x K PLM30 34 CASAPPA MOTOR x PLM30 38 CASAPPA MOTOR x Pumps BTTL1330 BERTOLINI PUMP (4300 PSI, 13 LPM) x L BTTK2130 BERTOLINI PUMP (4300 PSI, 21 LPM) x BRAL2035 BERTOLINI PUMP (5000 PSI, 20 LPM) x Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 13

PUMP PARTS TTL1330 Kit No. Part No. Description Pieces 127 B069872973 Full Oil seal & Sight Glass kit 10 123 B069867973 Valve Kit 12 95 B069833973 Seal Kit Minor 18 96 B069834973 Seal Kit Major 24 37 B069814973 Oil Seal Kit 3 67 B049839973 Valve cap kit 12 Item 48 B060020322 OIL FILLER PLUG WITH DIP STICK 1 For full pump parts list refer to www.aussiepumps.com.au 14 Aussie Hydraulic Drive Blaster Operation & Maintenance Manual

Sept 2014 PUMP PARTS TTK 2130 Kit No. Part No. Description Pieces 98 B069842973 Full Oil seal kit 9 123 B069867973 Valve Kit 12 89 B069839973 Seal Kit Minor 18 86 B069836973 Seal Kit Major 24 37 B069814973 Oil Seal Kit 3 67 Item 48 B049839973 Valve cap kit 12 OIL FILLER PLUG 1 WITH DIP STICK B060020322 For full pump parts list refer to www.aussiepumps.com.au PUMP PARTS RAL 2035 Kit No. 123 164 165 146 67 Part No. B069867973 B089835973 B089836973 B089816973 B049839973 Description VALVE KIT SEAL KIT MINOR SEAL KIT MAJOR OIL SEAL KIT CAP KIT O-RING & SIGHT 147 B089817973 GLASS KIT Item OIL FILLER PLUG B060020322 48 WITH DIP STICK Pieces 12 19 25 3 12 11 1 For full pump parts list refer to www.aussiepumps.com.au Aussie Hydraulic Drive Blaster Operation & Maintenance Manual 15

WARNING OVERSPEEDING Do not operate machine at over the maximum rpm. Over speeding can cause serious pump damage. EXCESSIVE BYPASS Do not run on excessive by-pass. Switch machine off within five minutes of ceasing operation as excessive by-pass can cause heat build up in pump and subsequent damage. Excessive bypass running voids warranty. HIGH PRESSURE SETTING The high pressure pump is factory set to operate at its rated pressure. DO NOT ADJUST. Tampering with the pressure regulator will void warranty and can be DANGEROUS. CHECK NOZZLE MONTHLY If pressure drops off check nozzle for wear. Nozzles should be replaced on a regular basis (every month for machines in regular use, every three months for machines used intermittently). Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be DANGEROUS to the operator. PRESSURE CLEANER DAILY CHECK LIST Check pump oil level Check nozzle for wear Check all HP components for leaks: Gun/lance, HP hose and all fittings Check water filter and clean if necessary Check unloader & safety valve for leaks THREE MONTHLY REGULAR SERVICE All professional machines need to be thoroughly serviced every three months. The service should include the following; Change pump oil Check filter for foreign debris Check unloader & safety valve for leaks Check all HP components for leaks: Gun/lance, HP hose and all fittings Replace nozzles SIX MONTHLY REGULAR SERVICE To maintain the Bertolini pump warranty (three years from date of purchase), the pump must be serviced by an authorised service agent every six months. Contact Aussie for your nearest agent. LOOK AFTER YOUR MACHINE AND IT WILL LOOK AFTER YOU! Australian Pump Industries Pty Ltd 7 Gladstone Road, Castle Hill NSW 2154 Ph: (02) 8865 3500 Fax: (02) 9894 4240 www.aussiepumps.com.au info@aussiepumps.com.au