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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
Hydraulic drive blasters
to 500 BAR (7,200 psi) coming soon
Australian Pump Industries
www.aussiepumps.com.au
REF: APHYDHPBVER1
Sept 2014
AUSSIE HIGH PRESSURE BLASTER RISK ASSESSMENT
MODELS:
MATERIAL CONSTRUCTION:
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:
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.
TTL1330 HYD
TTK 2130 HYD
RAL 2035 HYD



(Class A)
(Class B)
(Class B)
DESCRIPTION:
Hydraulic drive high pressure cold water blasters
designed for professional cleaning applications.
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:
CONSEQUENCES FOR PEOPLE:
A.
B.
C.
D.
E.
1.
2.
3.
4.
5.
Common or repeating occurrence.
Known to occur or “it has happened”.
Could occur, or “I’ve heard of it happening”.
Not likely to occur.
Practically impossible.
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.
Fatality or permanent disability.
Serious lost time, injury or illness.
Moderate lost time, injury or illness.
Minor lost time, injury or illness.
No lost time.
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
Controls must be taken to either eliminate or
minimise the risk.
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
Sept 2014
POTENTIAL HAZARD:
Yes/
No
Hazard
Entanglement with hose
(tripping, falling)
Yes
Injury from high pressure
water
Yes
Risk
Risk
Rating
Personal injury of the
operator or bystanders
13
Personal injury of the
operator or bystanders
13
Controls
 Warning stickers

hose reel option
 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
Sight damage
6
 Warning regarding wearing safety
Dislodged particles in
atmosphere
Yes
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
glasses.
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
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Sept 2014
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
**WARNING**
AUSSIE HEAVY DUTY WATER BLASTERS ARE DESIGNED FOR PROFESSIONAL OPERATORS ONLY
SYSTEM SPECIFICATIONS
Model
Stock Code
Pump
Pressure
(psi)
EWP
(psi)
Flow Hydraulic motor
rate
(lpm)
Hydraulic pressure Hydraulic flow
required (psi)
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.
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
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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
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Sept 2014
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
C
B
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.
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
Sept 2014
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
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Sept 2014
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)
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
Sept 2014
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
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Sept 2014
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
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
Sept 2014
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
Sept 2014
TROUBLE SHOOTING GUIDE
FAULT
CAUSE
Pump running normally but
pressure low on installation
Pump sucking air
Valves sticking
Unloader valve seat faulty
Nozzle incorrectly sized
Worn piston packing
Fluctuating Pressure
Valves worn
Valves blocked
Pump sucking air
REMEDY
Check water supply and possibility of air ingress.
Check and clean or replace if necessary
Check and replace
Check and replace
Check and replace
Worn piston packing
Check and replace
Check and replace
Check water supply and air ingress at joints in
suction line
Check and replace
Pressure low after period of
normal use
Nozzle worn
Check valves worn
Check valves blocked
Unloader valve seat worn
Worn piston packing
Cracked pistons from dry running
Check and replace
Check and replace
Check and clean
Check and replace
Check and replace
Replace pistons
Pump Noisy
Air in suction
Check water supply and connections on suction
line
Check and replace
Broken or weak suction or delivery
valve spring
Foreign matter in valves
Worn bearing
Excessive temperature of liquid
Check and clean
Check and replace
Reduce temperature
Presence of water in oil
Oil seal worn
High humidity in air
Piston packing worn
Check and replace
Check and change oil twice as often
Check and replace
Water dripping below pump
Piston packing worn
O.R plunger retainer worn
Check and replace
Check and replace
Oil Dripping
Travel plug in use on pump
Replace with breather plug
Oil seal worn
Check and replace if necessary
Leaking gun and/or pressure pipe.
Leaky sleeve
Worn out kick-back valve body
Renew gun, seal pressure pipe
Renew sleeve
Check and renew as necessary kick-back valve
plate and seat
Renew seals
Valves switches repeatedly
when gun is off
Leaky 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
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Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
Sept 2014
PARTS IDENTIFICATION
F
L
J
K
H
I
Position
F
H
I
J
K
L
Part No
Nozzles
C915035M
C915045M
C915055M
Lance
C3905.15
MPA40026100
Gun
CGPDG5010
Hose
AR206K2214X2X10
AHW06FB6FB6X10
Unloader
BVB350
Safety Valves
MPA60156000
MPA60058000
Strainer
AYSTRAINER3/4
Gauge
AGCDR0102
Hydraulic motor
PLM30 22
PLM30 34
PLM30 38
Pumps
BTTL1330
BTTK2130
BRAL2035
Description
TTL 1330
TTK 2130
RAL 2035
HP NOZZLE (15°ANGLE, TIP SIZE 035)
HP NOZZLE (15° ANGLE, TIP SIZE 045)
HP NOZZLE (15° ANGLE, TIP SIZE 055)
x
900MM SS DOUBLE LANCE C/W BOOT
S3-350 LANCE
x
5,000 PSI GUN
x
x
10 MTR HP HOSE (R2, 4500 PSI)
10 MTR HP HOSE (R2, 5,800 PSI)
x
x
UNLOADER VALVE (5100 PSI)
x
x
4000 PSI SAFETY VALVE
VS350 SAFETY VALVE (5100 PSI)
x
x
STRAINER 3/4”
x
x
x
6000 PSI GAUGE
x
x
x
CASAPPA MOTOR
CASAPPA MOTOR
CASAPPA MOTOR
x
BERTOLINI PUMP (4300 PSI, 13 LPM)
BERTOLINI PUMP (4300 PSI, 21 LPM)
BERTOLINI PUMP (5000 PSI, 20 LPM)
x
x
x
x
x
x
x
x
x
x
x
Aussie Hydraulic Drive Blaster … Operation & Maintenance Manual
x
x
13
Sept 2014
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
Item
48
B049839973
Valve cap kit
12
B060020322
OIL FILLER PLUG WITH DIP STICK
1
For full pump parts list refer to www.aussiepumps.com.au
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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