AUSSIE SAFE BLASTING

RAPTOR EXTREME

Mine Boss Hydro

-

Blasters

AUG 2019

SAFE OPERATOR INSTRUCTION MANUAL

SAFETY NO.1

Read this manual before using this blaster

Covers:

Raptor 18

Raptor 21

Raptor 24

REF: ARAPEXT_MANVER1

Aussie Pumps AUSSIE SAFE BLASTING

August 2019

AUSSIE HIGH PRESSURE BLASTER RISK ASSESSMENT

MODELS:

In line with the National Occupation Health & Safety Commission ’ s requirements the data below applies to the following Aussie high pressure water blaster models:







Raptor Extreme 18

Raptor Extreme 21

Raptor Extreme 24

DESCRIPTION:

(Class B)

(Class B)

(Class B)

Engine drive hydro blasters designed for professional cleaning applications.

MATERIAL CONSTRUCTION:

Aussie Raptor pressure washers are mounted on heavy duty trolley mounted frames. They consist of a quality internal combustion petrol engine driving a triplex style three piston high pressure pump. The machines are supplied with wheels for ease of portability and manoeuvrability. The machines can be supplied with hose reels and up to 45 metres of high pressure hose to increase operator convenience.

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 TABLE:

The consequences (loss outcomes) are combined with the likelihood (of those outcomes) in the risk ranking table to identify the risk rank of each loss event

(e.g. a consequence of ‘ Moderate ’ with a likelihood of ‘ Likely ’ yields a risk rank of

17).

The table yields a risk rank from 1 to 25 for each set of probabilities and consequences. A rank of 25 is the highest magnitude of risk that is a highly likely, very serious event.

A rank of 1 represents the lowest magnitude of risk, an almost impossible very low consequence event.

Controls must be taken to either eliminate or minimise the risk.

h o o d k e i l i

L

Use the matrix to determine the risk

Almost certain

Likely

Possible

Unlikely

Rare

Consequences

Insignificant Minor

High

11

Moderate

7

Low

4

Low

2

Low

1

High

16

High

12

Moderate

8

Low

5

Low

3

Moderate Major

Extreme

20

High

17

High

13

Moderate

9

Moderate

6

Extreme

23

Extreme

21

High

18

High

14

High

10

Catastrophic

Extreme

25

Extreme

24

Extreme

22

19

15

High

High

2 WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING Aussie Pumps

Risks associated with operating a high pressure cleaner … for use in daily SAFE WORK METHOD STATEMENT

Hazard

Entanglement with hose

(tripping, falling)

Risk

Personal injury of the operator or bystanders

Injury from high pressure water

Personal injury of the operator or bystanders

Risk

Rating

13

1

Controls







Warning stickers

hose reel option

Ensure firm footing before operating machine





















Warning notice on blaster

Wear eye protection & PPE

Use high pressure resistant gloves

Always point spray jet at area to be cleaned

Use barriers to keep bystanders away from work area

Stop if persons enter working area

Never leave machine unattended

Never point lance at any person or animal

Never put your hand over the spray nozzle when operating

Stop operating if a malfunction occurs

Suffocation Fatality is the risk

Ergonomic lifting or movement on site,

High temperature (from engine muffler and other components)

Battery exploding if not charged correctly

Personal injury

Burns from muffler

Acid burns

Fire or explosion Serious injury, burns 18

15

13

15

12

Noise

Dislodged particles in atmosphere

Slipping on wet surface

Contact with chemical cleaners used to clean surfaces

Hearing damage

Sight damage

Personal injury

Skin contact could result in burns, skin irritation etc.

Fumes from some chemicals may lead to respiratory problems

22

19

17

17













Do not operate engine without suitable ventilation

Operator training in working in confined spaces

Operator ’ s Manual

Staff training

Warning sticker on machine

Keep clear of hot engine parts





Warning sticker on battery

Wear eye & face protection when working near battery





Do not operate in explosive atmosphere

Turn off engine & allow engine to cool before refuelling

 Use of ear protection







Never clean asbestos

Use of eye protection with high pressure water

Use of proper footwear











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

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 3

Aussie Pumps AUSSIE SAFE BLASTING

August 2019

AUSSIE ECO CLEAN RAPTOR OPERATOR & MAINTENANCE INSTRUCTIONS

Contents:

Blaster Risk Assessment .............................................. 2

Warranty ...................................................................... 4

Safety precautions ....................................................... 5

Specifications ............................................................... 5

Assembly & preparation for use .................................. 6

Machine preparation .............................................. 6

Hose connections ................................................... 7

Before starting the machine ................................... 7

Starting the engine ................................................. 7

Stopping the machine ............................................ 7

Care & Maintenance .................................................... 8

Grit Blaster Instructions (optional accessory) .............. 9

Troubleshooting ......................................................... 10

Personal Protective Equipment ................................. 11

Operator ’ s Hand signals ............................................. 12

Accident Reporting .................................................... 12

Emergency Medical Information ................................ 12

Parts identification & Replacement parts ................. 13

Resetting the safety valve .......................................... 14

Pump parts ................................................................. 15

Warnings .................................................................... 16

Pressure cleaner daily checks .................................... 16

Three monthly regular service ................................... 16

CONGRATULATIONS on the purchase of an Aussie

Raptor professional high pressure water blaster.

These top of the range machines have been designed to be easy to use, simple to service and offer reliability and performance.

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.

GUARANTEE

4

… EXCLUSIVE 4 YEAR PUMP WARRANTY

This Aussie Eco Clean product is guaranteed against faults in manufacture for two years from purchase.

The Bertolini pump has a four 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.

Engine warranty is the responsibility of the engine manufacturer. Unit must be returned to authorised engine dealer for evaluation of engine warranty.

(Refer to engine handbook).

Battery warranty is covered by Federal/Ryde

Batteries, call (02) 9879 5422 for your nearest outlet.

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 .

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING Aussie Pumps

SAFETY PRECAUTIONS

-

IMPORTANT

NEVER direct the spray jet at any surface that may contain asbestos material.

1.

NEVER direct the spray jet at any person or animal. Keep hands and feet clear of the cleaning nozzle at all times.

2.

NEVER hold a finger over the high pressure nozzle.

3.

NEVER direct the spray jet at the machine itself or any electrical equipment.

4.

After use, release the pressure in the high pressure hose by operating the gun trigger.

5.

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.

6.

NEVER supply any liquid other than water to the pump inlet.

7.

DO NOT run dry

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 join hoses together to extend the length

(buy an extra long hose)

12.

DO NOT operate the machine whilst standing on ladders, use a platform tower or scaffolding.

13.

DO NOT operate if there is a chance ice has formed in the pump or hose. Thaw first.

14.

Operate in well ventilated areas only.

15.

DO NOT fill the fuel tank while engine is running or hot

16.

DO NOT try to repair a leak in the hose or connection while the system is under pressure.

17.

DO NOT substitute any component part on this machine. Use of incorrect parts could cause serious personal injury.

18.

Children must NOT be allowed to use the machine.

19.

Always use safety goggles and steel cap boots when using the machine.

SPECIFICATIONS

Model Stock code

Raptor 18 ABRAPTOR18 3TNV

Raptor 21 ABRAPTOR21 ETNV

Raptor 24 ABRAPT24 4TNV88

Engine Pump

Model

Pump Pressure

(psi)

Flow rate

(lpm)

Engine rpm

Yanmar 3 TNV88 RA1850 7,300 PSI

Yanmar 3 TNV84T RA2150 7,300 PSI

Yanmar 4 TNV88 RA2150 7,300 PSI

18

21

24

2400

2400

2400

Note: Certification of the operator is mandatory for Class B machines … refer to AS/NZS4233.1.

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 5

Aussie Pumps AUSSIE SAFE BLASTING

August 2019

ASSEMBLY AND PREPARATION FOR USE

Before proceeding with assembly of your new Aussie Eco

Raptor high pressure blaster, check that all parts listed below are included.

A. Machine Preparation (initial start

1.

up)

Check the oil in the pump. With the machine on a level surface the oil level should cover the red spot in



1 x 500 bar gun lance assembly





1 x 500 bar high pressure hose

1 x high pressure hose restraint the oil level sight glass on the side of the pump. If necessary, top up pump with SAE 75W 90.

Do not mix different grades of oil as this may affect the machines performance. If alternative oil is used,



1 x 500 bar protective apron

Gun/hose/restraint Set Up:







Slide hose protector over the hose end.

Screw on the hose to gun nipple

Attach restraint to attachment plate

2.

3.

Breather plug pump first empty out oil by unscrewing drain plug in bottom of machine.

Ensure breather plug is fitted to pump.

WARNING : Before operation ensure top mounted travel plug is replaced by breather plug. 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.

Check oil level in engine, check engine manual for details of oil to use.

Aussie Safety Protection Kit

Detergent injector

4.

Check fuel level and fill if necessary. (unleaded petrol)

B. Hose Connections

1.

Connect gun/lance assembly to high pressure hose.

Use hose restraint between gun and hose as per

Safety Standard AS/NZS 4233.1

for Class B machines.

2.

Check inlet water filter is clean then connect water

6

Safety valve

UNLOADER SETTING

The high pressure unloader on the machine is factory set to operate the pump at it ’ s rated pressure.

DO NOT ADJUST. Tampering with the unloader will void warranty and can be dangerous.

Unloader factory set,

DO NOT adjust

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING Aussie Pumps supply hose to machine. Use a 25mm (minimum) hose . Flush out hose before connecting to remove any obstructions.

Incoming water supply must deliver double the flow of the machine. If questionable, check supply at machine. If supply is insufficient, do not operate from this outlet. Connect only to clean town water supply.

Warning: Do not operate from tank or pond. Doing so will cavitate the pump causing damage.

Cavitation or pump starvation is not covered by warranty. Cavitation is a phenomenon causing vacuum pockets to form within the pump that eventually implode under pressure pitting the internal pump surfaces.

7.

Pull trigger of gun while starting the engine.

8.

9.

10.

11.

Select ’ Power ON

Increase throttle to fully open position. End stop has been set to maximum 2400 rpm. end stop.

Do not adjust this

Check that there are no leaks in the line connections, gun or power lance. If leaks are detected they must be fixed before using the machine.

’ press the green start button. This will initiate the start sequence checks and the engine will automatically start once these are complete.

Release gun trigger. button on control panel and then

C. Before starting the machine

OPERATE IN WELL VENTILATED AREAS ONLY .

1.

2.

1.

Ensure machine is level

2.

Turn on water supply.

D.

Starting the engine

1.

Connect supply hose, turn on water supply and fill break tank. NOTE: Tap should be left fully open while machine is running.

2.

Turn on fuel valve.

3.

Connect battery at battery isolator.

4.

Ensure engine throttle is fully turned down.

5.

Pull the gun trigger to expel air from the system.

Water will trickle from the end of the lance when all the air is expelled.

6.

Ensure emergency stop button is reset and open the front of the control panel.

3.

6.

4.

8.

10.

Emergency Stop Button

All Class B machines are fitted with a mandatory emergency stop, as per safety standard AS/NZS4233.1.

If the emergency stop button has been used, it will need to be reset before the engine will start again. To reset, turn the button clockwise.

This should only be used in an emergency.

WARNING Immediately after activating the E -

Australian Pump recommends de throttling the engine and running with no load before stop move control power button the OFF position. Failure to do so could result in a flat shutting off the engine by selecting off button.

battery or shortened battery life.

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 7

Aussie Pumps AUSSIE SAFE BLASTING

August 2019

12.

Pressure begins when the gun trigger is squeezed.

STORAGE

KEEP THE MACHINE OUT OF MOISTURE LADEN

ATMOSPHERES

Store the washer in an upright position, preferably drained of water if there is a danger of freezing (or fill with anti freeze).

G. Stopping the machine

PUMP CRANKCASE LUBRICATION

1.

2.

Allow machine to run for 1 minute without load to cool before stopping.

Select the red off button on control panel.

Proper pressure washer pump crankcase lubrication will help extend the working life of the machine. Follow these important guidelines. We recommend keeping a simple service log book.

3.

4.

5.

6.

7.

8.

This blaster is fitted with an emergency stop button.

After activation, turn engine key to off and reset stop button by rotating until it pops out.

Switch the Power Off on the control panel.

Battery isolator can be locked off to prevent blaster from operating.

Turn off water supply.

Pull gun trigger to release all pressure in the system, then LOCK THE TRIGGER.

Hoses may now be disconnected from the machine.

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.

CARE AND MAINTENANCE:

AFTER EACH USE

If cleaning agents have been mixed with the incoming water, it is essential 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.







Change pump oil every 40 hours of use high quality oil. (SAE 75W 90)

Pump oil level can be checked with the dip stick under the breather cap or by viewing the oil sight gauge where fitted. The oil level is correct if level is in the centre of the gauge. If oil level is low, fill to correct level with recommended oil (SAE 75W 90).

DO NOT OVERFILL CRANKCASE!

Replace oil in gearbox (separate chamber) with SAE

90 gear oil every three months.

PREVENTATIVE MAINTENANCE



















Rinse filter in supply hose connection regularly.

Use correct size nozzles for machine and replace when worn, check serial tag for correct size.

Drain water from pressure hoses, gun/lance assembly and accessories after use.

Protect pump from freezing. Failure to remove water from the pump in freezing temperatures will result in damaged pump manifold.

Use ONLY injector of the size and type designed for this model.

DO NOT tamper with unloader valve adjustment or alter engine speed.

DO NOT siphon chemicals through the pump, it is designed for water only.

Incoming water supply must not exceed 60°C, otherwise pumps seal damage could result

Follow engine manufactures guidelines for engine maintenance. (see engine manual)

8

DO NOT RUN EXCESSIVE BY

-

PASS

SWITCH MACHINE OFF WITHIN TWO MINUTES OF

CEASING OPERATION AS EXCESSIVE BY PASS CAN CAUSE

HEAT BUILD UP IN PUMP AND SUBSEQUENT DAMAGE .

EXCESSIVE BY PASS RUNNING VOIDS WARRANTY!!

WARNING:

CHECK NOZZLES AND REPLACE IF WORN

If pressure drops off, check nozzle for wear.

Nozzles should be replaced every 40 hours. Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be dangerous to the operator.

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING

AUSSIE GRIT BLAST INSTRUCTIONS (optional accessory)

Aussie Pumps

GRIT BLAST HEAD SET UP INSTRUCTIONS WARNING: To reduce the risk of injury, always protect eyes and face with safety glasses and mask, and hands and arms with heavy work gloves when spraying abrasive materials.

1.

Fit grit blast gun/lance kit at end of high pressure hose, in place of normal gun/lance assembly.

2.

Lodge sand probe into sand bag. Note the sand must be dry.

3.

Connect and open the water supply line to the blaster before starting the pressure washer.

4.

Squeeze the gun trigger to bleed air as normal keeping the tip of the gun pointing down.

5.

Turn on the pressure washer and squeeze the gun trigger to activate the spray.

CAUTION: Always test spray on a scrap of similar material first! The high pressure spray could damage the surface if the grit blaster is held too close.

6.

To determine best distance for grit blasting, start with the spray nozzle a metre away from the surface and gradually move closer, frequently checking the surface for damage.

7.

Always point the nozzle downward when not spraying. This prevents water from entering the sand supply. If water does get into the sand supply hose, remove the probe from the sand, hold the gun trigger open, and let the hose air dry. Always be sure the sand hose is dry before using.

8.

Keep the sand covered to prevent the overspray from wetting the sand. Do not allow small pieces of the sand bag to fall into the sand supply as they could prevent the flow of sand.

1.

2.

3.

4.

5.

6.

Unwind the tail coupling and remove top of the blast head. Screw in the nozzle to the tail.

Replace the tail and ensure that the tip of the nozzle is a minimum of 28mm from leading edge of body and a maximum of 36mm. The fan spray from the nozzle should be perpendicular to the sand intake tail. Mark the top side of the hexagonal coupling for reference.

Check angle of jet from nozzle

Min 28mm

Line up the dimple in the ceramic nozzle perfectly with the sand intake tail and hold in place with the holder. Screw down the head locking nut.

The fan produced by the two nozzles must be aligned.

Connect grit blast head to hp gun/lance and activate the gun with the high pressure blaster running. Check the fan jet leaving the nozzle is the full width of the slot. Adjust by rotating hexagonal tail coupling, ensuring that the marked side of the tail always finishes on top.

With the high pressure washer turned off, connect the sand hose to the sand intake tail and secure with hose clips.

Sand intake tail

Head locking nut holder ceramic piston with dimple

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 9

Aussie Pumps AUSSIE SAFE BLASTING

TROUBLE SHOOTING GUIDE (for engine troubleshooting refer to engine manual)

FAULT

Pump running normally but pressure low on installation

CAUSE

Pump sucking air

Valves sticking

Unloader valve seat faulty

Nozzle incorrectly sized

Worn piston packing

REMEDY

Check water supply & possibility of air ingress.

Check & clean or replace if necessary

Check & replace

Check & replace

Check & replace

August 2019

Fluctuating Pressure

Pressure low after period of normal use

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

Pistons cracked as a result of dry running

Check & replace

Check & replace

Check water supply & air ingress at joints in suction line

Check & replace

Check & replace

Check & replace

Check & clean

Check & replace

Check & replace

Replace pistons

Pump Noisy

Air in suction

Broken or weak suction or delivery valve spring

Foreign matter in valves

Worn bearing

Excessive temperature of liquid

Check water supply & connections on suction line

Check & replace

Check & clean

Check & replace

Reduce temperature

Presence of water in oil

Oil Dripping

Water dripping below pump

Unloader switches repeatedly when gun is off

Oil seal worn

High humidity in air

Piston packing worn

Safety valve activated due to pressure spike

Thermal dump activated

Piston packing worn

O.R plunger retainer worn

Travel plug in use on pump

Oil seal worn

Leaking gun &/or pressure pipe.

Leaky sleeve

Worn out kick back valve body

Leaky seals

Check & replace

Check & change oil twice as often

Check & replace

Reset safety valve (see page 11), if it keeps activating replace unloader

Activates if water temperature exceeds 60°C. Should self reset once water in pump cools. If not, replace

Check & replace

Check & replace

Replace with breather plug

Check & replace if necessary

Renew gun, seal pressure pipe

Renew sleeve

Check & renew as necessary kick back valve plate & seat

Renew seals

Leaky piston rod pressure

Leaky by pass at nominal

Pressure gauge shows high pressure fluctuations when shutting off gun

Pressure in supply line when running on by pass

Engine will not start

Defective O Ring/Support Ring

Nozzle too small, too much water.

Worn out by pass valves

Valve set too high above operating pressure

Dirty valve

Renew piston rod seals & examine surfaces in guide case

Install larger nozzle

Examine & renew as necessary

Adjust the unloader at the operating pressure.

Clean valve (removing lime deposits etc).

Grease parts before installing.

Dirty or worn low pressure valves

Out of fuel

Engine defect

Remove & clean or replace low pressure valves

Fill tank with petrol/diesel

Return to engine service agent

10 WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING

Personal Protective Equipment … STAY SAFE

Aussie Pumps

 Head Protection.

Where appropriate suitable head protection complying with AS/NZS 1801 should be worn.

 Eye Protection.

Eye protection complying with AS/NZS 1337 (adequate for the purpose and of adequate fit on the person) should be worn at all times when in the vicinity of water blasting operations. Where liquid is liable to cause eye damage, full visor and goggles are recommended.

 Body Protection.

All persons should wear suitable waterproof clothing complying with AS/NZS 3765.1 (or AS/NZS 3765.2 if working with hazardous chemicals), having regard to the type of work being undertaken. Liquid or chemical resistant suits should be worn where there is an assessed risk to health or of injury that can be prevented by such equipment.

 Hand Protection.

Appropriate personal protective equipment should be worn where:

Adequate hand protection complying with the recommendation/s of AS/NZS 2161.2, AS/NZS 2161.3 or

AS/NZS 2161.5 should be worn when there is an assessed risk of injury that can be prevented by such equipment.

 Foot Protection.



 hazards cannot be otherwise prevented or suitably controlled, e.g. by engineering or administration controls, total enclosure or substitution; and/or complete protection is essential, e.g. in some occupational environments with uncertain levels of hazards.

The provision and use of personal protective equipment does not reduce or replace the need for proper

Occupational Health and Safety prevention measures, such as engineering or administrative controls to be undertaken.

Recommendations of such preventative measures should always be fully explored before considering issue of personal protective equipment. Where personal protective equipment is issued, instruction and training should be provided regarding its correct use and maintenance.

All persons should wear appropriate occupational protective footwear complying with AS/NZS 2210.2. A lower leg guard should be used by water blasting operators where it is assessed that the risk of foot injury could be prevented by such equipment. AS/NZS

2210.1 provides guidance for the selection of footwear.

 Hearing Protection.

Suitable hearing protection complying with AS/NZS

1270 should be worn at all times when the noise levels exceed limits set by regulatory authorities.

Comfort, function & Safety … at an affordable price

Aussie Pumps supply a full range of personal safety protection gear rated to 500 BAR (7,300 psi) … call for details or check online … www.aussiepumps.com.au

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 11

Aussie Pumps AUSSIE SAFE BLASTING

OPERATOR ’ S HAND SIGNALS

August 2019









This section provides a set of hand signals for communication when carrying out water jetting operations .

 Pressurise System

Thumb pointing upwards, the rest of the hand closed.

From the shoulder height the arm moves up and down.

Depressurise System.

Form a fist. Move the arm back and forth at shoulder height.

Raise Pressure.

First finger pointing up, the rest of the hand closed. The hand is moved in a circular motion.

Lower Pressure.

First finger pointing down, the rest of the hand closed.

The hand is moved in a circular motion.

ACCIDENT REPORTING



 Medical Recommendation .

If an accident occurs where pressurised water penetrates or appears to have penetrated the skin, medical assistance should be sought immediately.

 Immediate First Aid .

Where medical examination is not immediately possible

(e.g. in remote situations), appropriate basic first aid measures should be applied and the patient observed closely until medical treatment is available.

 Medical Alert Card .

All operators engaged in commercial and industrial water blasting operations should carry out an immediately accessible, waterproof medical alert card. This card should:

 outline the possible nature of injuries and post accident infections that can be caused by high pressure water blasting;

 provide details of immediate first aid treatment until medical treatment can be arranged; and

 provide the name or names of medicos (and contact phone numbers) who should be contacted for expert medical advice for the treatment of high pressure water blasting injuries.

In addition, the card may also:

 identify the worker; and

 outline medical information about the worker; e.g. blood type, allergies and conditions, such as asthma.

EMERGENCY MEDICAL INFORMATION

Reporting .

All accidents or injuries, whether resulting in “ lost time ” or “ no lost time ” injuries, should be recorded in accordance with the recommendations of AS 1885.1.

Incidents that result in “ near misses ” should also be recorded as a means of providing a record of significant incidents that have the potential to result in serious injury at the workplace, so appropriate measures can be implemented to minimise or eliminate these potential hazards.

Immediate hospital attention should be given to personnel who sustain equipment related injuries while operating the system. In such cases, it is vital that medical personnel be apprised of all facts relevant to such injuries.

Therefore, all operating personnel should be provided with waterproof emergency medical tags or cards describing the nature of their work and the possibility of injury inherent in the use of a water blasting device. The tag or card should also bear the following standard notice:

Personal Injuries .

In the event that a person is injured by the impact of a water jet, the injury caused may appear insignificant and give little indication of the extent of the injury beneath the skin and the damage to deeper tissues. Although only a small hole may be present, quantities of water may have penetrated the skin and entered the flesh and organs causing serious injury.

12 WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING

PARTS IDENTIFICATION & REPLACEMENT PARTS

K

J

Aussie Pumps

H

L

I

G

F

A

E

Position

H

I

J

G

D

E

F

C

A

K

L

Part No

Nozzles

M0124006210

M0124006310

M0124006410

Gun/lance

MPA30473000

Hose & Restraint

A3641443309

AD HRSS10

Unloader

BVB53

Safety Valves

MPA605020000

Filter

HVF150

AYSTRAINER1 ”

Gauge

AGAUGE600BAR

Drive Belt tba

720 8m 50 (A7208M50)

720 8m 50 (A7208M50)

Pump

BRA1850

BRA2150

BRA2450

C

D

Description

HP CERAMIC TIP NOZZLE (15°ANGLE, TIP SIZE 030)

HP CERAMIC TIP NOZZLE (15°ANGLE, TIP SIZE 035)

HP CERAMIC TIP NOZZLE (15°ANGLE, TIP SIZE 040)

500 BAR GUN LANCE ASSEMBLY

30 MTR HP HOSE (500 BAR)

HOSE RESTRAINT

UNLOADER VALVE (550 BAR)

VS500 SAFETY VALVE

FILTER

Y STRAINER

600 BAR GAUGE

DRIVE BELT

DRIVE BELT

DRIVE BELT

BERTOLINI PUMP (7,200 PSI, 18 LPM)

BERTOLINI PUMP (7,200 PSI, 21 LPM)

BERTOLINI PUMP (7,200 PSI, 24 LPM)

Raptor 18 Raptor 21 Raptor 24 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 13

Aussie Pumps AUSSIE SAFE BLASTING

August 2019

Resetting the Safety Valve … ONLY TO BE CARRIED OUT BY QUALIFIED SERVICE TECHNICIAN

SAFETY VALVE

D

C

UNLOADER

A

B

The safety valve prevents damage to the pump seals and valves caused by a pressure spike.

The safety valve should only be reset after checks to ensure the unloader valve is working correctly. If in doubt contact, your nearest Aussie Eco clean service centre.

5.

With the pump running at the required pressure, the adjusting screw (D) on the safety valve should be wound out until there is a slight drip. Screw it in one quarter of a turn, or until the drip stops, this will set the safety valve 10% over the required pressure.

The lock nut (C) should then be locked off. Paint mark to identify any tampering.

The following steps should be taken to reset the safety valve, with the unit running.

1.

Unscrew the lock nut (C) on the safety valve and the adjusting the hex knob (D), it should be screwed in all the way.

6.

Repeat running with the trigger open and then closed two or three times to ensure safety valve doesn ’ t blow off pressure.

7.

If safety valve continues to trip contact your nearest

Aussie Eco clean service centre .

2.

Loosen the lock nut (B) on the unloader and wind the unloader knob (A) in gradually until the required pressure is obtained whilst the trigger is pulled and water is running through the pump. Do not exceed the maximum rated pressure of the pump.

3.

The lock nut (B) should then be wound up to meet the adjusting nut. The small grub screw in the locking ring should be screwed in to secure.

4.

Paint mark across the nut and knob to identify any tampering with the setting.

14 WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual

August 2019

AUSSIE SAFE BLASTING

PUMP PARTS RA1850, RA2150, RA2450

Aussie Pumps

Order the right part first time … specify the pump model number when ordering parts.

Full parts breakdowns available online … www.aussiepumps.com.au

Kit No.

BKIT211

BKIT146

BKIT210

BKIT209

BKIT228

BKIT227

Part Number

B089840973

B089816973

B089839973

B089838973

B089846973

B089845973

B080070182

Description

Valve Cap kit

Oil seal kit

Sight glass, O ring & gasket kit

Valve kit

Seal kit major

Seal kit minor

Ceramic pistons 20mm

Pieces

18

3

10

18

19

13

3

FREE pump service guide available

WORK SMART … STAY SAFE | Aussie Raptor (Class B) … Operator ’ s Instruction Manual 15

WARNINGS

OVERSPEEDING

Do not operate machine at over 2400 rpm (engine speed).

Over speeding can cause serious pump damage.

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.

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.

PRESSURE CLEANER DAILY CHECKLIST

1.

Check pump & gearbox oil level

2.

Check engine oil level

3.

Check nozzle for wear

4.

Check all high pressure components for leaks, damage, wear or corrosion.

a. gun/lance b. High pressure hose c. all fittings

5.

Check water filter and clean regularly

6.

Check unloader, safety valve and thermal dump for leaks

BEWARE of abrasions on hose and replace if damaged

… STAY SAFE

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 .

THREE MONTHLY REGULAR SERVICE

All professional machines need to be thoroughly serviced every three months. Use an approved and qualified Aussie service agent. The service should include the engine manufacturer ’ s recommendations

(see separate Engine Manual) and the following:

1.

Change pump & gearbox oil

2.

Check filter for foreign debris

3.

Check unloader, safety valve and thermal dump for leaks

4.

Check all HP components for leaks: Gun/lance, HP hose and all fittings

5.

Replace nozzles

6.

Check gearbox to engine key for wear, and replace as required. NB Damage generated by worn keys is not covered by warranty.

SERVICE ADJUSTMENTS

Note only qualified approved technicians should carry out adjustments or major service work on these pumps.

Australian Pump Industries Pty Ltd

7 Gladstone Road, Castle Hill NSW 2154

Ph: (02) 8865 3500 Fax: (02) 9894 4240 www.aussiepumps.com.au [email protected]