Australian Pump Industries Aussie Hydro-Loop System OPERATION & MAINTENANCE MANUAL SERIES HSS SERIES HSC March 2010 IMPORTANT: TO REDUCE RISK OF INJURY, READ OPERATING INSTRUCTIONS CAREFULLY BEFORE USING EQUIPMENT Aussie Hydro-Loop System … Operation & Maintenance Manual 1 Australian Pump Industries TABLE OF CONTENTS Introduction .......................................................................................................................... 3 Statement of Warranty Safety Warnings ................................................................................................................... 4 Operating Instructions Before start up ........................................................................................................... 6 Operation ................................................................................................................... 6 Shut Down & antifreeze protection ............................................................................ 8 System Information Power system ............................................................................................................. 9 Pumping System ........................................................................................................ 9 Heating System .......................................................................................................... 11 Pressure Delivery System .......................................................................................... 12 Accessories ................................................................................................................ 13 Troubleshooting Guide ......................................................................................................... 16 Burner Troubleshooting guide .............................................................................................. 18 Service/Maintenance Information ........................................................................................ 20 Service Log .......................................................................................................................... 21 Exploded Views & Parts Lists ............................................................................................. 22 Waste Water Recovery Unit Technical Data ........................................................................................................... 28 Recovery Unit Instructions ........................................................................................ 29 Recovery Unit Troubleshooting ................................................................................. 30 Common Replacement Parts for Recovery Unit ........................................................ 30 Exploded View & Parts List ........................................................................................ 31 Trailer Information ................................................................................................................ 32 Specifications of Steam Cleaner: Hydrotek Model Pump EWP Flow rate (lpm) Pump Make Pump Model Engine Pump rpm HSS32004HB 3200 4785 15 Bertolini TMG4040 Honda Petrol 13HP HSC40006HB 4000 6485 21 Bertolini KTV3021 Honda Petrol 24HP 3200 1450 HSCU5106V 5000 8500 21 General Pump TSP1821 Vanguard Petrol 29HP 1450 HSC35003DG 3500 5200 13 General Pump EZ303634U1 Kohler Diesel 10.3HP 1450 HSC40006D12 4000 6485 21 Bertolini TTK4365 Kubota Diesel 17HP 1450 2 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries INTRODUCTION CONGRATULATIONS ON THE PURCHASE OF YOUR AUSSIE HYDRO-LOOP SYSTEM YOUR RESPONSIBILITY: This operator’s manual was compiled for your benefit. By studying and following the safety, installation, operation, maintenance, and troubleshooting information contained within, you can look forward to many years of trouble-free service from your equipment. Every person who will operate the equipment must read and follow the safety warning and operating instruction sections of this owner’s manual prior to use. You are responsible for operating the product properly and safely. You are also responsible to follow the maintenance schedule on the back page of this manual to keep your warranty active. not an authorized service centre. 8. Labour is not paid on added accessories such as surface cleaners, hose reels, wastewater recovery and filtration. WARRANTY PROVIDED BY OTHERS: PETROL and diesel engines and some electric motors are warranted by the manufacturer of the component and their warranty is provided through the manufacturer’s service centres. BIG 6 COIL REPLACEMENT: Should the heater coil leak under normal conditions within the first FREIGHT DAMAGE: If delivered by a trucking company, please 6 years of service, Aussie Pumps will provide a replacement coil inspect for any concealed freight damage and note this on the free of charge. Failure from freezing is considered neglect and is paperwork from the trucking company before signing. Should you therefore excluded. Freight and installation labour is not covered. find damage has occurred during shipping, do not return the damaged merchandise to Aussie Pumps, but file a claim GENERAL CONDITIONS: immediately with the freight carrier involved. Aussie Pumps’ responsibility with respect to claims is limited to making the required repairs or replacements to the original retail QUESTIONS: Help us provide you with the fastest service. Please user, and no claim of breach of warranty shall be cause for any locate the enclosed warranty registration card and return it to cancellation or rescission of the contract of sale of any Aussie Aussie Pumps to register your machine. If problems occur, contact Hydrotek product. the dealer you bought your machine from, a local authorized Aussie Pumps service centre, or call the Aussie Pumps factory and Aussie Pumps reserves the right to change or improve the design ask for technical services. of any of its products or illustrations without assuming any obligation to modify any product previously manufactured. THERE ARE NO USER SERVICEABLE COMPONENTS ON THIS EQUIPMENT. Aussie Pumps is not liable for indirect, incidental or consequential damages including any cost of substitute equipment, loss of GETTING STARTED: If your dealer has not prepared the machine revenue, pecuniary expense or loss, or inability to use a Aussie for start up, you may need to connect the hose to the pressure Hydrotek product. Aussie Pumps disclaims all implied warranties, outlet on the washer and connect the other end of the hose that including those of merchantability and fitness for use for a swivels to the trigger gun inlet and tighten. Mobile Wash Skids are particular purpose. Some states do not allow exclusions or engine powered and shipped from the factory with the fuel tanks limitations on how long an implied warranty lasts, so the above empty, the battery cables disconnected, and the battery dry (if exclusions may not apply to you. It is the buyer’s responsibility to included on engine powered units). Fill the battery to the fill line ensure installation and use of Aussie Pumps Hydrotek products with electrolyte (available at a local auto parts store), connect the conforms to local codes. battery cables, and follow the operation instructions for starting. HOW TO OBTAIN WARRANTY SERVICE: Pressure Steamers are electric powered and will require an 1. List washer model# _______________________________ appropriate electric outlet or disconnect box and an electric plug that is rated for your machine’s voltage and amperage and List serial# ______________________________________ matches to your electrical socket. Smaller machines are equipped (on base plate of machine near the motor). with a ground fault interrupter on the electrical cord and you will 2. Contact your local service dealer and return the Aussie need to press the reset button after it is plugged in. (See Hydrotek washer or part within the warranty period along with Operating Instruction section and enclosed page on Installation your sales receipt. To locate service, call Aussie Pumps and Guidelines). ask for technical services or go to: www.aussiepumps.com.au. 3. You also have the option to obtain a return goods NO-NONSENSE GUARANTEE: Aussie Pumps promises to repair authorization and ship the questionable part freight prepaid Aussie Pump Hydrotek power washers if defective in materials or directly to the factory. The part will be evaluated upon receipt. workmanship for one year from the date of original retail purchase If found defective, Aussie Pumps will repair or replace part including the cost of PARTS and LABOUR, but you must pay under the conditions of warranty and return to you. transportation costs and travel time. 4. If the defective component is an engine or motor made by another manufacturer, we, or your authorized Aussie Pumps Items and Conditions Not Covered: dealer, can help you obtain warranty service through the 1. Normal wear items such as discharge hose, guns, wands, specific manufacturer’s local authorized service centre. spray arms, nozzles, quick couplers, o-rings, pump packing, brushes, filters, belts, and tires. Please enclose a copy of the dated receipt and explain the nature 2. Cost of regular maintenance/adjustments or damage from lack of the defect. of maintenance. 3. Damage due to freezing, abrasive fluids, chemical deterioration, and scale build-up. 4. Damage from fluctuation in electrical or water supply. 5. Any product or part that has been altered, modified, over pressurized, misused, or has been in an accident. 6. Dealer installation or damage from improper installation of the machine or alteration by a dealer or promise of additional warranty from dealer. The factory warranty is not transferable from the dealer to the retail purchaser on used or rented equipment. 7. Labour is not paid if the dealer that serviced your machine is Aussie Hydro-Loop System … Operation & Maintenance Manual 3 Australian Pump Industries SAFETY WARNINGS WARNING THIS EQUIPMENT CAN BE HAZARDOUS TO THE OPERATORS SAFETY AND ONLY AUTHORIZED PERSONNEL WHO HAVE READ AND UNDERSTOOD THE O P E R AT O N M AN U AL SHOULD BE PERMITTED TO OPERATE THIS UNIT. NEVER ALLOW CHILDREN TO PLAY ON OR AROUND THIS EQUIPMENT. 7. Use only in a dry area. Do not handle electrical cords and plugs when they are wet, when your hands are wet, or when standing in water. Do not spray high-pressure water on to the machine. 8. Disconnect power supply before making any repairs or adjustments. 9. Transformer on burner is 20,000 volts. Disconnect battery cable before servicing burner or engine on 12-volt systems. FIRE PRECAUTIONS: ELECTRICAL PRECAUTIONS: 1. Observe all State, Local, and National codes for the installation of your electrically powered washer. 2. For a grounded product rated 250 volts, single phase, or less: This product is provided with a ground fault circuit interrupter built into the power cord plug. (7.5hp single phase excluded; order GFCI separately). If replacement of the plug or cord is needed, use only identical replacement parts. 3. GROUNDING INSTRUCTIONS: Cord Connected, Grounded Products: This product must be grounded. If it should malfunction, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. The product is equipped with a cord having an equipmentgrounding conductor. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances. DANGER – Improper connection of the equipment grounding conductor can result in a risk of electrocution. Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. Do not modify the plug provided with the product, do not cut off the ground pin – if it will not fit the outlet, have a proper outlet installed by a qualified electrician. Do not use any type of adaptor with this product. 4. To comply with the national electric code, this pressure washer should only be connected to a receptacle that is protected by a ground fault circuit interrupter (GFCI). 5. EXTENSION CORDS: Use of extension cords is not recommended. 6. NEVER operate an electrically powered washer after it has tripped a breaker or a ground fault device without have the reason for the trip determined by an authorized service engineer or competent electrician. 4 1. DO NOT use improper fuels or solvents in this equipment, and only fill with the correct fluids when the unit is in an OFF condition, main power is disconnected, and engine and burner are cool. 2. Fill the diesel burner fuel tank with diesel fuel, kerosene, or approved alternate fuel. NEVER use PETROL. Do not confuse PETROL and diesel fuel tanks. 3. NEVER operate this equipment in the presence of flammable vapours, dust, gases, or other potentially combustible materials. 4. AVOID contact with the exterior of the coil/ heat exchanger assembly, mufflers, and exhaust port or stack to prevent burns. 5. DO NOT store fuel or other flammable materials near the burner or any other open flame. 6. Diesel fired or PETROL power units are designed for outdoor use and installation only. 7. Burner on/off switch must be placed in the OFF position when the pressure washer is not being used. D o not depend on engine run switch to turn the burner off – this may cause a safety hazard. 8. Warning: Burner (water heater) should start only when water is sprayed. Stop the system/ engine immediately if burner continues to fire when trigger gun is off. VENTILATION PRECAUTIONS: 1. Do not run engine or burner in an enclosed area. Exhaust gases contain carbon monoxide, an odourless, deadly poison. 2. Observe all State, Local, and National codes providing for indoor use or installation of this unit. 3. Provide adequate ventilation to prevent engine overheating and inefficient burner combustion (min. 2’ air space). Do not restrict normal engine airflow. 4. For engine driven units mounted in a van or Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SAFETY WARNINGS box truck type vehicles, provide an external engine exhaust line that is larger in diameter than the factory exhaust pipe and vent the exhaust to the outside of the vehicle, but not below the vehicle’s interior floor height. Also, insure adequate fresh air circulation within the van for engine cooling purposes to prevent heat build-up and for engine fresh air intake. Clearance of at least 12” is recommended on all sides of the unit. Provide a burner exhaust vent, at least 8” diameter, to the outside through the van roof, or though the side panel that is at least 10” in diameter, and position this vent to avoid water, dirt and debris collection. 5. No flammable liquids, aerosols, or flammable materials should be stored within 24” of the unit and should not be stored under the unit. During refueling, ALL ignition sources and switches should be OFF and there should be a person with the proper fire extinguisher and training within the vicinity of the unit in case of fire. Unit should not be left running unattended or out of site. SPRAY INJECTION PRECAUTION: alert – Watch what you are doing. 4. Always wear protective eye goggles when operating the equipment. Additional protective items such as a rubber suit, gloves, and respirators are advisable, particularly when using cleaning detergents with a corrosive content. 5. Know the detergents you are using. Read and follow the directions on the detergent labels. PERSONAL HAZARD: 1. Shut unit off and disconnect power before removing belt guards or electrical covers. 2. Shut unit off before moving it. 3. NEVER lock the trigger on the gun valve in the on position. 4. Do not exceed recommended operating pressure or temperature. 5. Observe all regulations when towing trailer mounted units. 6. Keep hands clear of belts: Some units equipped with auto-on may start at any time when power is connected. 7. Do not operate the product when fatigued or under the influence of alcohol or drugs. 1. Never direct spray jet at any surface that may contain asbestos material. 2. Fluid from high-pressure spray or leaks can penetrate the skin and cause serious injury. If any fluid appears to penetrate the skin, get emergency medical help at once. DO NOT treat as a simple cut. Tell the physician exactly what fluid was injected. For treatment instructions, have the physician call your local poison centre. Without proper treatment, complications can develop. 3. WARNING – Risk of injection or severe injury to persons – Keep clear of nozzle. DO NOT direct discharge stream at people. This machine is to be used by trained operators. Keep operating area clear of all people. Use only 48” long wands on machines producing over 3000 PSI. Also, only use straight wands or wands with a bend of 10° or less. CAUTION: Hot discharge fluid – DO NOT touch or direct discharge stream at people. Gun kicks back – Hold with both hands. Stay Aussie Hydro-Loop System … Operation & Maintenance Manual 5 Australian Pump Industries OPERATING INSTRUCTIONS BEFORE START UP: Read all instructions If the opening on your battery box measures 9” by 6”, we recommend Exides’ U1L/GTH 235CCA battery. Deep cycle batteries are 1. CHECK PUMP OIL: Check pump oil by recommended to extend battery life. Always locating the oil view window. Depending on connect the positive battery cable before the your pump model, fill to the red dot or to the negative and coat the battery terminals with top of the site glass window. corrosion inhibitor to prevent corrosion. Do not reverse polarity. 6. If accessories, or discharge hose are not installed, see your local dealer for instructions & installation. WARNING CHECK TRIGGER ON SPRAY GUN IS OFF & CHEMICAL VALVE IS CLOSED WARNING DO NOT OPERATE MACHINE WITOUT ADEQUATE WATER SUPPLY. 2 . CHECK FLUID LEVELS: Check engine oil OPERATION: and coolant levels if unit is so equipped. (See the maintenance schedule on page 20). 1. STARTING: 3. CONNECT HOSE & GUN ASSEMBLY. Petrol Engine Units: Turn engine power switch to the on position, choke if necessary and turn key to start position only until engine starts. On units with a rewind starter, pull cord rapidly. 4. CONNECT THE WATER SUPPLY & FILL TANK: Be sure there always sufficient water in Diesel Engine Units: Turn power switch to heat the glow plugs for a tank, do not run dry. maximum of 30 seconds and 5. BATTERY INFORMATION: release. Turn the Batteries are available through your dealer. power switch to the Depending on the type of battery you start position only purchase, you may have to fill it with until engine starts. electrolyte (available at local auto parts store). (Do not use starter WEAR EYE PROTECTION! fluids.) 6 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries OPERATING INSTRUCTIONS continued 6. BYPASS MODE: 2. PURGE AIR FROM SYSTEM: System will go into bypass mode when Squeeze the trigger on the spray gun until a machine is left running and trigger gun is constant stream of water comes out. (Purging closed. Bypass mode is when the inlet water works best with nozzle removed from wand coming into the pump re-circulates through the and/or dual wand in the low-pressure mode.) unloader across the pump head. If left in bypass too long – more than five minutes – 3. SELECT DESIRED NOZZLE friction created by the movement of the water Connect nozzle securely to spray wand. If will begin to heat the water at a rapid rate. If equipped, close pressure-adjusting knob on equipped with a THERMAL DUMP VALVE, dual wand. Hold gun firmly, squeeze trigger for water exceeding 62°C will cause the valve to high pressure spray. open allowing the cool water in. The valve will reset itself when water temperature comes down to a safe level. If equipped with a bulk water tank, water can be bypassed back through the tank allowing for a larger volume of water to be re-circulated through the pump head thus reducing heat on the pump seals. If equipped with By-pass-cool system, a small portion of the bypass water is routed back through the float tank to keep the pump cool. CAUTION – Gun kicks back – hold with both hands. WARNING – risk of explosion spray flammable liquids. – DO NOT 4. START BURNER: To create hot water on high pressure washers equipped with heat exchangers, release the trigger on the gun, turn the burner to the “on” position, and turn the thermostat to the desired temperature. WARNING DO NOT LEAVE IN BYPASS FOR LONGER THAN FIVE MINUTES TO PREVENT PUMP FROM OVERHEARTING. SHUT OFF UNIT WHEN NOT SPRAYING WATER. WARNING Cool down burner before shutting off. Squeeze the trigger on the spray gun and the burner will begin heating the water. It will stop firing whenever the water spray is off or if the temperature setting is exceeded. 5. STEAM: Insert green steam nozzle and turn thermostat to 250°F steam setting. The steam nozzle is sized for approximately 25% less water volume than the hot water mode. Aussie Hydro-Loop System … Operation & Maintenance Manual 7 Australian Pump Industries OPERATING INSTRUCTIONS continued 7. SET CHEMICAL INJECTION: If unit is equipped with inlet chemical injection, place chemical pickup tube in pre-mixed chemical solution and open chemical valve for desired chemical concentration. Rinse and close valve after use, do not use harsh chemicals through the inlet injector system. Drawing air into the chemical tube by leaving the chemical valve open will cause the pump to lose pressure and may cause pump damage. away from the surface and using the broad spray nozzle works best to perform rinsing and delicate surface washing. In areas where the cleaning is more difficult and in smaller areas such as cracks and holes, use the narrow spray nozzles, 0 or 15 degree. Chemicals can be applied in a couple of different ways. One way is with a hand spray pump. The other is with the chemical system on the equipment; either downstream or high pressure depending on the system you have. When using the high-pressure chemical system, do not use any caustic chemical as this may cause damage to the pump. For very harsh chemicals, it is best to use a hand sprayer. First wet the surface and wash off heavy debris. Test the surface to be sure the chemical won’t harm it. Then apply the chemical and let it work in for couple of minutes before rinsing. Do not allow chemicals to dry on the surface. If unit is equipped with a downstream chemical injector, connect the chemical injection assembly into the high-pressure discharge hose quick connects. Place the chemical pickup into chemical solution and turn brass collar to adjust concentration. The chemical will inject only when you drop the outlet pressure by opening the valve on the dual wand or changing to a low-pressure nozzle. Soap the surface from the bottom up. Close When rising off the chemicals always start from the top down. When finished using the chemical, chemical valve when not in use. be sure to rise out the chemical line and valve with fresh water to prevent clogging. MAINTAIN PH BETWEEN 5 & 9 8. If equipped with an AF2 (2) gun operation, select “50%” nozzle from panel and insert into coupler on spray gun for full pressure output when using two guns at the same time. Flow can be reduced by selecting flow reduction nozzles only when one operator is using the machine. Maximum temperature is 93°C. WASHING TECHNIQUES When washing, always start from the bottom up, and do the final rinse from the top down. This will keep the water from streaking the surfaces that are being cleaned. When applying chemicals, it is also best to start from the bottom and work up. In areas where there is no grease or oil present, and the dirt is loose, cold water will be sufficient. When it comes to grease, oil, and hard to clean dirt, hot water and/or chemicals can make the job easier, and speed up the cleaning process. For applications that require even more heat and where water use/runoff must be minimized, switch to the steam mode (if equipped) and adjust the thermostat for up to 250° steam. For general washing use a broad pattern spray nozzle such as the 40-degree nozzle. Backing 8 SHUT DOWN 1. Turn burner switch to the off position. 2. Rinse & close chemical valve. 3. Squeeze the trigger on the spray gun until the water becomes cool. 4.Turn motor/engine switch off with the appropriate controls. Turn off diesel engine units by pulling the throttle kill lever. 5. Turn off water supply. 6.Squeeze trigger to release any trapped pressure in discharge hose. 7. Disconnect & store hoses. 8. Antifreeze equipment: In the event that the equipment is not to be used for an extended period, store in heated space or antifreeze the unit. Run the machine until the float tank is near empty, fill with a 50% mix of water and antifreeze and run until antifreeze appears at the high-pressure outlet. If unit is equipped with a blowout valve, it may be blown out with compressed air in addition to using antifreeze solution. On direct feed units (no float tank), use a 5’ garden hose to draw the antifreeze mix from a bucket or blow out the unit with compressed air until only air and no water comes out of the discharge. Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SYSTEM INFORMATION loosening the mounting bolts on the pump and generator to permit them to slide. Turn the To maintain appearance of the power washer, horizontal rail adjusting bolts to tighten belts until use stainless steel cleaner on the stainless steel they deflect ¼ “ to ½” with finger pressure. panels. DIRECT DRIVE: Pump is bolted directly to the motor/engine. If pump needs to be removed, do POWER SYSTEMS: not force off by prying or damage may occur. When reassembling, coat the entire motor shaft PETROL ENGINE: With the proper care and maintenance, your with heavy grease, or a generous amount of antiPETROL engine will give years of trouble free seize and use “thread locker” or “lock tight” on mounting bolts. service. Please follow the Service and Maintenance Guide and the enclosed engine sheet or contact GENERATOR: your local authorized engine dealer for Some self-contained hot water units (SC and maintenance and repairs. Use unleaded PETROL with an octane rating of SCU Series) are equipped with a 115v, 2900w 87 or higher in the engine fuel tank. Consult generator to power the diesel burner. The engine manual for proper oil type and capacity. generator output voltage must be between 110 to The engine manufacturer recommends a break- 130 Volts, (or between 59 to 63 Hz.), when the in period of 25 hours at which time the engine oil unit is under full load. If the generator voltage and filter should be replaced. Thereafter, change falls out of this range, the RPM of the engine will oil every 50 hours and the filter every 100 hours need to be adjusted to proper speed. If the (see engine manual). Do not rely on the low oil engine cannot maintain the proper RPM, do not shutdown (if equipped) as a reminder to add oil. use the burner or any power from the generator The engine manufacturer will typically not until the engine is repaired. An AUXILIARY warranty engine damage from lack of oil even if OUTLET is available on some SC or SCU Series the low oil system failed. On machines with a machines for running wastewater recovery systems, light, or other accessories off of the 115V generator or a 12V burner, the throttle is preset at the factory (See generator. A maximum of 1500 watts of 115v Generator section). Engines include backfire power is available when the burner is on or 2000 watts when it is off. A switch/circuit breaker prevention solenoids. located on the control panel will need to be reset if the circuit is overloaded. Use of a ground fault DIESEL ENGINE: The diesel engine, although it has a higher initial interrupter is recommended when plugging in cost, can save money with lower fuel accessories or lights to the auxiliary voltage consumption and longer life. Use clean diesel outlet. To extend generator life, make sure the fuel and do not allow engine to run out of fuel or burner and all auxiliary power is off when the the system will have to be bled to restart the engine is started or stopped. Keep generator dry. engine. Clean the fuel filter periodically with kerosene PUMPING SYSTEM: (See Engine Manual). Use 10w – 30 oil with API classification CC/CD grade rated for diesel PUMP: The pump is a positive displacement, oil engines in the engine crankcase and change bath crankcase, and triplex plunger type. It every 50 hours. If the engine is water cooled, use contains 3 plungers, which move forward and a 50/50 mix of antifreeze/de-ionized water backward in a cylinder to propel water past 3 inlet solution and check daily. Never use more valves and 3 discharge valves into a highantifreeze than water or damage to the engine pressure manifold. The crank case oil window should be checked for oil level and clarity and the could occur from overheating. pump for oil or water leaks before each use. The sight window is located at the rear (opposite the POWER TRANSMISSION: head) of the pump and should be filled to the red WARNING: Shut off power. dot with non-detergent 30w pump oil, available at BELT DRIVE: Check belt condition, alignment your Aussie Hydrotek dealer. If the oil becomes and tension periodically. Replace belts when they milky in color, moisture is entering the crankcase. show signs of wear or cracking. Tighten belts by Change the oil and contact your authorized APPEARANCE: Aussie Hydro-Loop System … Operation & Maintenance Manual 9 Australian Pump Industries SYSTEM INFORMATION continued Aussie Hydrotek dealer if the problem persists. covered under warranty. Keeping filters clean and checking for air in pump feed lines can prevent cavitation and increase pump life. Do not run pump in the bypass mode (pump running with the trigger gun off), for a period of more than 5 minutes or the pump will begin to overheat (maximum water temperature is 62°C). Do not run pump dry. Protect from freezing. Do not run a frozen pump until it is completely thawed. An optional DOWNSTREAM INJECTOR is available if harsh chemicals need to be applied. The downstream injector will apply chemicals only at low pressure, by installing black soap nozzle or opening spray wand valve if equipped. If equipped standard with downstream injection, adjust concentration level by turning brass collar on the injector, or the knob on pump or control panel. Read and follow all safety instructions on the detergent label. UNLOADER AND PRESSURE RELIEF VALVE: The unloader valve is preset at the factory to govern the proper output pressure of your machine. It will release the pressure of the pump back into the inlet if the trigger on the spray gun is released. NEVER increase the set pressure on the unloader to exceed the specifications for your machine. All hot water machines are equipped with a SAFETY PRESSURE RELIEF VALVE. In the unlikely event that your unloader fails, or if the burner overheats and builds excessive pressure, the pressure relief valve will vent the pressure into the atmosphere. If this occurs, turn off the machine and have it checked by an authorized dealer. The pressure relief valve will automatically reset itself. WATER SUPPLY: An adequate water supply to the pump must be maintained at all times. If the inlet flow is too low or if there is air in the water supply, the pump will run rough, pulsate and lose pressure. Maximum inlet water temperature is 62°C. Do not restrict inlet water supply. If the pump is run dry, it can quickly overheat. The water is filtered by a garden hose adapter screen. Clean and replace as required or install a large capacity strainer to insure a clean supply of water. BURST DISC TECHNOLOGY: This additional safety feature functions to protect the coil from the heating system and high system spikes of pressure. If this component ruptures, you should take the machine in to an authorized Aussie Hydrotek dealer. Do not plug off and continue to run. CHEMICAL INJECTION SYSTEM: With an inlet chemical injection system, the chemicals are introduced at the inlet of the pump and controlled with a chemical metering valve. The pump is fed by a float tank to create a light vacuum, not to exceed negative 3psi, which draws up the chemical into the inlet manifold of the pump, mixes it with water, and sprays it out of the nozzle under high pressure. Open the chemical valve only when the pickup tube is submersed in a solution or air will enter the pump causing the pump to lose pressure and run rough. Do not use highly corrosive detergents or acid type cleaners, and be sure to rinse and close the chemical valve after each use or the chemical line and check valve may become obstructed. Chemicals should be between 5-9 PH. Consult Aussie Hydrotek for chemical compatibility. Chemical abuse is not 10 Bulk tank water supply: Large capacity water supply tanks can be used with most units if water is not readily available at the washing site. Belt driven, low speed pumps (less than 1750 RPM) can draw from a tank if you ensure that the vacuum does not exceed negative 3psi. A 80 mesh, 200 micron strainer and a ¾” I.D. or larger suction hose must be used to maintain a clean and adequate water supply. Larger flow (810gpm) machines require 1” feed and filtration. Be sure that the water supply is free from air or damage to the pump may result. Periodically you should clean out the strainer and water supply Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SYSTEM INFORMATION continued equipped with either a pressure switch or a flow switch to control the burner. When the trigger on the spray gun is squeezed, water begins to move through the coil and pressurize. The flow/ pressure switch turns the burner on and begins USING DE-IONIZED OR SOFTENED WATER IN to heat the water. Whenever the water spray YOUR POWER WASHER: Do not use de-ionized stops or if the water is shut off, the burner will water through the coil on a hot water machine or shut off. coil corrosion will result. Water softeners, however, will reduce coil scale deposits and WARNING: Burner should fire only when the should be installed if your water is especially trigger is squeezed and spraying water, if it comes on at any other time, shut off machine and hard. have it serviced. DIAGNOSTIC LIGHT: The burner diagnostic light HEATING SYSTEM: on the rocker switch (if equipped) can help in COIL/HEAT EXCHANGER SYSTEM: The heat determining problems with the burner. The red exchanger contains a continuous coil of pipe, light indicates that power is going to the fuel which forms a cold water jacket around the solenoid valve. The burner should be firing and outside of the heating area. It is double wrapped heating the water whenever the red light is on. with ceramic blanket insulation and a stainless When the trigger on the spray gun is released or steel cover. The inside of the coil assembly can if the temperature set point is exceeded, the red become covered with soot if the burner is out of light will go off and the burner will stop firing. adjustment or if it is fired by diesel fuel. This can SYSTEM INFORMATION 9 be cleaned by removing both end caps on the DIESEL FIRED BURNER: The diesel-fired burner coil enclosure and brushing or spraying off is a forced draft pressure-atomizing burner. debris, or by adding a soot removal agent (Part Diesel fuel is sprayed out of an atomizing nozzle, #CB200) to the diesel fuel. Both a diesel fuel mixed with air, and ignited by a high voltage pressure gauge and smoke test device is spark. The flame is directed towards the coils of required for proper burner adjustment, and must pipe, which in turn, heats the water flowing be performed by a qualified technician. When the through it. Use clean DIESEL FUEL for the water is heated, scale (calcium) will begin to form burner. on the inside of the coil pipe depending upon the hardness of the water in your area. To remove AIR BAND adjustments may need to be made to build-up in the coil, use a scale remover (Part compensate for higher elevations, or if more than #CB100) available at your authorized Aussie a trace of smoke is observed in the burner Hydrotek dealer. Perform this descaling service exhaust. The ELECTRODES may need to be only when a noticeable pressure drop is detected cleaned and adjusted periodically. These across the coil. Follow directions to avoid adjustments have to be made precisely and should be performed only by qualified personnel. damage. Set between #1 & #2 on the smoke gauge. Wear safety glasses. tank to remove debris that may accumulate on the bottom. If a water supply tank and a float tank are both utilized, a special three way valve can be used to switch between tanks. The FUEL PUMP is a self priming, low volume pump which is propelled by the burner motor. The fuel pump pressure is typically set at 100 PSI but can be turned as high as 140 PSI during the winter when the incoming water temperature is lower. Before adjusting the fuel pressure, connect a fuel pressure gauge and an outlet water temperature gauge, turn the pump and burner on, and turn the fuel pressure screw clockwise until the desired water temperature is STEAM INSTRUCTIONS: If your unit is steam obtained. Be sure not to exceed the commended capable, install the green steam nozzle, turn specifications of the machine. thermostat to 250° F. The FUEL FILTER will need to be replaced often PRESSURE/FLOW SWITCH: The burner is if the diesel fuel quality is poor. A fuel filter with a TEMPERATURE SWITCH: The burner is equipped with a high temperature limit switch, which will shut off the burner when the water temperature becomes too hot. Hot water machines are equipped with an adjustable thermostat so that the operator can control the outlet water temperature. The burner will automatically cycle on and off to maintain the desired temperature. Aussie Hydro-Loop System … Operation & Maintenance Manual 11 Australian Pump Industries SYSTEM INFORMATION continued water separator is recommended if the fuel couplers are also used on most wands so they can be interchanged. quality is consistently poor. The FUEL SOLENOID is an electric fuel valve that shuts off the fuel whenever the trigger on the spray gun is released or if the set temperature on the heat switch is exceeded. TRIGGER GUNS: The trigger gun is merely a valve that turns water spray on and off. If it begins to leak or fails to shut off, replace or repair the valve assembly. The IGNITION TRANSFORMER provides a high voltage spark that travels down the electrodes to ignite the diesel fuel. Disconnect all power before servicing. The 12V burner operates from the battery on the SS Series (and a limited number of SC Series). The engine has a 15 to 20 amp charging system that keeps the battery charged which runs the burner. The burner motor and transformer stop when the trigger gun is released and is controlled through a high amperage contactor. To help keep the battery fully charged, and for safely cooling down the burner, turn off the burner during the last minute of rinsing. When leaving the machine unattended, shut off burner and engine switch. Replace 12 VDC battery regularly (2 year maximum interval) on 12V burner systems to help ensure consistent performance. Never lock any gun in the on position for any reason. Never point spray at a person or any part of the body. SPRAY WAND: Wands are available in 2 to 6 foot lengths for various cleaning applications. If the unit is equipped with a dual wand, you can adjust the pressure by turning the knob on the valve to divert part of the water through the lowpressure nozzle. PRESSURE DELIVERY STYSTEM: DISCHARGE HOSE: Use only a wire braid hose rated for the output pressure and temperature of the machine. Single wire braid hoses are generally rated from 2500 to 4000psi. Additional hose lengths can be added with quick twist couplers with a minimal loss in pressure of about .5 PSI per foot. Inspect hoses for wear and replace if necessary. Avoid kinking or running over the hose to extend the hose life. WARNING: Aussie Hydrotek hot water machines require a special 120°C rated hose to operate in the steam mode. If the hose is not replaced when worn or if it is not replaced by a Aussie Hydrotek original equipment hose, it may burst and serious injury and burns could result. QUICK COUPLERS: The swivel connectors on the high-pressure hose and quick couplers on the spray nozzle make it easy to change nozzles or hoses. When connecting hoses or nozzles, be certain that the collar on the quick couplers snap into the locked position to prevent them from becoming loose. If the quick connect begins to leak, replace the O-ring (specify Viton or EDPM material) located in the female socket coupler. Grease the coupler periodically to make it work smoothly. Replace if it becomes worn. Twist 12 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries ACCESSORIES NOZZLES: The spray nozzle is a precisely machined orifice made of hardened stainless steel. The orifice size is matched to the output of your machine to attain the proper flow and pressure in which your machine was designed. The orifice, or hole, of the nozzle will enlarge with wear. For optimum performance, replace the spray nozzle to maintain the full output pressure of your machine. The 0° nozzle sprays a straight stream which impacts the surface very hard but does not cover a very wide area. Use the 0° red nozzle with care because it can damage the surface you are spraying with its high impact and long reaching spray. The 15° yellow nozzle sprays out a flat stream at a 15° width. It gives you less impact power than the above, but covers a wider area with one pass The nozzle installed on your machine from the of the spray wand. As you back away, the factory is designed to allow only about 90% of spraying nozzle from the surface, the spray the water being pumped to discharge out of the impact will decrease. nozzle. The remaining 10% is bypassed back into the inlet water supply by the unloader/ The 25° green nozzle is wider than the 15° and is regulator valve. If an incorrect nozzle size is most commonly referred to as the “steam used, the maximum flow and pressure of the nozzle”. The steam nozzles are sized to spray machine cannot be achieved and the pressure less water than the other high-pressure nozzles, so the water is discharged at a higher unloader valve can wear prematurely. temperature. (Up to 120°C.) When replacing the nozzle, match to one size under the flow and pressure output of the pump. The 40° nozzle spreads the water stream over a The nozzle is usually connected to the wand with wide area to give you less impact for delicate a quick coupler. Be sure the collar on the quick surfaces. coupler snaps into the locked position, or the nozzle could be lost when the trigger on the OPTIONAL ACCESSORIES: spray gun is squeezed. WET SANDBLASTER: The wet sandblaster is a Never connect the spray nozzle directly to the system that introduces sand (or other media such trigger gun without a wand or injury could result. as baking soda) into the water stream for Never place hands or fingers over the nozzle tip. abrasive blasting. It is especially effective for graffiti or paint removal. The nozzles generally come in four different spray angles: 0°, 15°, 25°, and 40°. The different spray angles of a given size of nozzle does not change the output pressure of the machine, just the impact force and surface coverage of the water spray. Performance of the unit is directly related to the output of your high-pressure washer. The sand is mixed with the water at the sand head in a tungsten carbide nozzle. A vacuum is created in the sand nozzle, which draws a sand and air mixture up the sand hose. If the sand becomes wet or the sand nozzle becomes plugged, the vacuum will be lost and the sand will quit flowing. The sand probe can be poked directly into a bag Aussie Hydro-Loop System … Operation & Maintenance Manual 13 Australian Pump Industries ACCESSORIES continued or bucket of sand to draw it up the sand hose. Do not cover the air intake port on the top of the sand probe or the sand flow will be disrupted. Uncoil the sand hose completely before use to improve the sand flow and replace the sand hose when it becomes worn. The carbide sand-mixing nozzle can be unscrewed and replaced when worn. Use bagged silica sand for best results through the sandblaster. Use 16 to 20 grit (course) sand for rust or concrete. Use 30 grit (fine) for fine metal surfaces or wood. Do not use wet sand or mix different grits of sand. A sand hopper is available for convenient sand storage. An air valve is available for adjusting feed rate on the hopper and should be fully open when using fine media such as baking soda. Always use safety goggles and protective clothing when operating the wet sandblaster. TURBO NOZZLE: The “Rotomax” type nozzle can be used up to 170°. Turn off burner or reduce temperature setting before using. Simply remove regular spray nozzle, replace with the turbo nozzle and squeeze the trigger on the spray gun. Do not point the turbo nozzle upward when starting. EXTENSION HOSES: connecting additional hose lengths by means of twist couplers can extend the length of your high-pressure discharge hose. Specify maximum pressure and temperature of your machine when ordering. Low-pressure inlet garden hoses are available in 50’ and 100’ lengths. Premium quality, 200psi rated hoses are recommended. HOSE REELS: Hose reels are available for convenient and quick storage of both discharge and inlet hoses. Different hose reels options are available for trailer mounting, machine mounting, or as base mount options. To keep the hose from unreeling, lock the drum in place and secure the gun or the end of the hose or it may drag on the road. The low-pressure hose should be of sufficient quality that it will not flatten out when reeled up, or water supply to the machine will be cut off. If the reel swivel begins to leak, replace or connect the hose directly to the machine until the leak is repaired. Hose reel swivels with lubrication are pre-lubricated at the factory. Additional lubrication intervals depend on application and frequency of use. However, a minimum for re-lubrication at 40 hours is recommended. Standard Moly-Lith grease is recommended. Do not over grease. Using a hand held grease gun, dispense one pump of grease into the grease fitting. Depress the ball bearing at the end of the grease fitting to allow the grease and air to escape. WARNING: Replace discharge hose with original equipment hose rated for 120° C, available at Aussie Hydrotek dealers. AUSSIE SPINNER – Surface Cleaners: The Aussie Spinner is a flat surface cleaner that connects to a pressure washer and uses a spray bar rotating at a high speed within 1” of the ground. It will clean concrete more consistent than an operator with a spray wand, with less fatigue, and 10-20 times faster. Simply move the twister over the surface and watch a clean path appear behind the unit. The Aussie Spinner can be used with hot water up to 90º C on most models for extra stubborn grease or grime, eliminated the need for soap pre-treatment in most applications. Rated to be used with a pressure washer up to 4000psi and up to 37lpm. See your dealer for proper nozzle size configurations to match your pressure washer. 14 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries ACCESSORIES continued WASTEWATER RECOVERY CONTAINMENT AND HydroTwisters with vacuum recovery capability are also available. Aussie Hydrotek accessories include Hydro Vacuum®, a product line of mobile wastewater recovery accessories. Starting with containment berms to divert wash water away from storm drains and toward a vacuum pickup device. The vacuum system can be used to simply pickup and transfer the water to a bulk tank or filter the water for washing reuse or sanitary sewer disposal. Vacuum system choices are either fully portable (on wheels) or truck or trailer mount systems. Dispose of collected wastewater properly: Permits can be obtained to dump wastewater into a sanitary sewer system if properly treated and tested. It is illegal to allow wash water to run into storm Aussie Hydro-Loop System … Operation & Maintenance Manual 15 Australian Pump Industries TROUBLE SHOOTING PROBLEM PROBABLE CAUSE (The most recurring probable cause is listed first) REMEDY (Repairs should only be made by a qualified technician) Power System: PETROL or Diesel Engine Driven Engine will not start or crank over Engine will not start but will crank over Engine bogs down under load whenever spray gun is triggered Battery dead. Dirty battery connection. Battery cables disconnected. Engine, pump, or gearbox is seized. Key-switch, solenoid and starter on engine defective Engine power switch is off or defective. Low oil shut down is activated. Low water switch engaged or defective (not on all models). Low on fuel. Fuel filter is clogged. Engine flooded or starved. Engine needs to be repaired or replaced. Operating in high elevation. Carbon deposits on cylinder head Charge or replace battery, add electrolyte if battery is new. Clean connections / Carefully check polarity. Connect or replace damaged cables. Replace or repair seized part. Repair or replace. Check engine power switch. Add oil to engine, check more frequently. Add water to bulk tank feeding pressure washer. Fill with appropriate fuel, bleed injector pump on diesel engine. Replace or clean fuel filter Choke only as required. See engine manual or engine dealer. Lower the pressure on the unit and check for correct engine speed (RPM). Remove head and wire brush deposits. Power System: Electric Motor Driven Electric motor does not start No electric power. Thermal overload in the motor or starter has been tripped. Power switch inoperative. Electric motor or wiring failure. No water to inlet. Machine will not autostart (if equipped with ETS or ITS) Must have adequate water supply. Scale build-up in coil. Check filter screen & inlet pressure. Inlet flow switch defective / jammed with debris. Check cord, plug, socket, and breaker. Reset manual overload by depressing the thermal switch on the outside of the motor or starter after the motor has cooled. CAUTION! Automatic overload will restart the motor automatically when it has cooled. Check power switch. Replace or repair motor and/or wiring. Connect water supply. 25 PSI minimum. De-scale coil for better water flow. Remove spray nozzle and pull trigger to check auto-start function. Check mechanical function & electrical signal to relay. Pumping System Trigger gun leaks or will not shut off Debris in gun valve assembly. Clean valve assembly or replace gun. Pump runs but has low spray pressure Water turned off. Nozzle is plugged or sized incorrectly. Inlet chemical injection valve is open without the end of the pickup tube inserted into detergent. Coil on hot water machines is obstructed. Priming of pump after run dry. Nozzle not installed. Dual wand valve is open. Leaky discharge hose or quick coupler. Water sprays out around nozzle. Inlet strainer clogged. Worn or wrong size nozzle. Belt slippage. Unloader valve worn or improperly adjusted. Air leak in inlet plumbing. EZ start valve is leaking. Turn water on. Clean or replace with proper size. Close soap valve or submerge detergent pickup tube into solution. Clean obstruction or scale deposits from coil with coil cleaner. Crack open fitting on high-pressure outlet of pump. Pump runs but has low spray pressure Install nozzle. Close dual wand valve and install highpressure nozzle. Replace hose, quick coupler, or o-ring in the quick coupler. Clean and check more frequently. Replace with nozzle of proper size. Tighten or replace with correct belt Install pressure gauge on pump head to adjust pressure. Check valve seat on unloader. Reseal fittings and inspect inlet hoses for air leaks. Remove hose to check for internal leaks. Remove hose to check for internal leaks. Pump runs but there is erratic, Inadequate incoming water supply. fluctuating pressure Stuck inlet or discharge valves. Restricted inlet or air entering the inlet plumbing on pump. Leaking High Pressure seals Leaking Low Pressure seals Broken or worn bearing or connecting rod in crankcase Increase water supply flow. Clean out or replace worn valves. Check fittings and hose for airtight seal, clean inlet strainer screen. Replace seals. Pressure feed the pump and replace L.P. seals if water leaks from the pump head. Replace pump or bearing. Loose drain plug or damaged seal Locate point of oil leakage and replace damaged o-ring/seal. Excessive crankshaft play or loud, knocking noise in pump Oil leaking from pump 16 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries TROUBLE SHOOTING continued PROBABLE CAUSE (The most recurring probable cause is listed first) REMEDY PROBLEM (Repairs should only be made by a qualified technician) Inlet injection will not siphon chemical Water is emitted from the chemical pickup tube Downstream injector will not siphon chemical Pressure relief relieving water Burst disk relieving water Check valve in strainer clogged. Chemical valve not open or clogged. Strainer not submerged in solution. Detergent hose cut or kinked. Check-valve malfunctioning. Clean or replace. Rinse after each use. Open chemical valve or clean. Submerge strainer and replenish chemical. Inspect hose, replace as necessary. Brass knob on injector is closed. Unit not in low-pressure mode. Detergent hose cut or kinked. Strainer plugged or not submerged. Internal injector parts corroded or stuck. Outlet water temperature too high. Un-loader failure/Coil overheating/ Excessive pressure. Excessive over-pressurizing and system spikes. Open by turning counter clockwise. Open dual wand or install low-pressure tip. Inspect hose, replace as required. Check screen on strainer pickup tube. Disassemble, clean or replace. Use with cold water (150° Maximum) Repair or replace check-valve. Turn machine off, wait a few minutes and restart. If problem continues, take in for repair. Take in for system check. Battery Battery keeps losing voltage (For 12v systems) Battery voltage low. RPM too low. Engine charging system faulty. Electrodes misadjusted. Fuel pump pressure too high. Air band too far open. Burner amp draw too high. Have battery checked and load test, charge if low and replace if necessary. Allow water to cool 2 minutes before shutting off engine. Engine RPM should be 3600 RPM with no load. Check engine charging system – must have 16 amp output. Adjust electrodes to maximum 1/8” gap. Fuel pump pressure should be approximately 100 to 110 PSI. Adjust for proper burn. Check amp draw of burner motor – should be 11 amp or less. Check amp draw of transformer – should be 4.8 or less. Water Temperature Discharge water temperature exceeds recommended operating temperature Discharge water temperature not reaching maximum operating temperature Burner input too high for conditions. Decrease fuel pump pressure and/or fuel nozzle size. Water flow restricted. High temperature limit switch faulty or set too high. Burner input too low for conditions. Clean or replace nozzle of proper size. De-scale coil and clear obstructions. Replace or reset temperature limit switch. Increase fuel pump pressure and/or fuel nozzle size. Burner System – Diesel Fired Refer to Burner Troubleshooting Chart on following pages Aussie Hydro-Loop System … Operation & Maintenance Manual 17 Australian Pump Industries TROUBLE SHOOTING continued 18 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries TROUBLE SHOOTING continued Aussie Hydro-Loop System … Operation & Maintenance Manual 19 Australian Pump Industries MAINTENANCE INFORMATION While your pressure washer has been produced with quality materials and craftsmanship, you as the owner have certain responsibilities for the correct care of the equipment. Attention to regular preventative maintenance procedures will assist in preserving the performance of your equipment. Contact your Aussie Hydrotek dealer for maintenance. A small investment in preventative maintenance will add many hours to the life of your pressure washer. Perform maintenance more often under severe conditions. Do not spray highpressure water onto the machine. Not all maintenance items apply to all machines. MAINTENANCE SCHEDULE** Engine Oil Air Cleaner Inspect Daily Change After first 8 hours then every 50 hours especially in high ambient temperatures Filter Every 100 hours Inspect Every 50 hours Clean Every 3 months Diesel Engine Coolant Check daily (maximum 50% antifreeze) Battery Level Check monthly 12V DC Burner Systems: Replace battery every 2 years Engine Fuel Filter 500 hours or 6 months Spark Plug Maintenance 500 hours or 6 months Clean Fuel Tank(s) Annually Replace Fuel Lines Pump Oil Inspect Annually Change Daily After first 25 hours, then every 6 months or 500 hours Axial pumps come filled with synthetic oil, which does not require changing Clean/Replace Burner Filter Monthly (More often if fuel quality is poor) Remove Burner Soot Annually Burner Adjustment/Cleaning Annually De-scale Coil Annually (More often if required) Replace Spray Nozzle Every 6 months Replace Quick Connects Annually Clean Water Screen/Filter Weekly Clean Float/Supply Tank Every 6 months Replace HP Hose Belts Annually Tighten Every 6 months Inspect/Replace Annually Trailer Tires/Bearings Monthly (Check tires for condition, tighten lug nuts, grease & check bearings) MAINTENANCE INFORMATION DESCRIPTION OIL TYPE CAPACITY Gas Engine 10w 30 motor oil ** .63 to 3 qt. Diesel Engine 10w 30 API cc/cd 3.25 qt. Pump, Cat Hydraulic, non-detergent 10w 40 ISO 68 11 – 42 oz. Pump, AR Non-detergent SAE 30w 10 – 41 oz. Pump, General, non-detergent SAE 30w 11 – 42 oz. Check the engine manufacturer’s service guide for additional maintenance items and specific high ambient temperature oil selection 20 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SERVICE LOG Date Checks made Comments Aussie Hydro-Loop System … Operation & Maintenance Manual 21 Australian Pump Industries SC EXPLODED VIEW 22 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SC PARTS LIST (Jan 09 effective s/n 200900178) 1 HSC00 2 BC225 3 B0029 4 BN053 5 BN125 6 BN053 7 B0088 8 BC480 9 B0089 10 HHP15 11 B0017 12 BC850 13 B2324 14 BN126 15 BZ250 BZ300 BZ325 BZ350 16 BPA13 17 BF015 18 BU600 19 BM513 20 EWC08 21 BMT23 22 UP137 UP045 23 DC568 24 DEB66 25 VS005 26 VS003 27 DE586 28 DH034 29 DE066 30 UPB80 31 UPB05 32 D1061 33 HHA00 34 DE568 35 D8044 38 DC568 39 D7061 40 DE866 DE766 42 UU323 UU371 UU375 43 D8068 44 DE566 45 D1061 47 VS030 48 DHC80 49 DF599 50 WT07R 51 WT081 52 WT080 53 WT078 54 DFF04 55 DFE04 56 DE866 57 D2088 58 D8088 59 D6088 64 D0021 65 D009M 67 HRR07 70 PH411 PG563 SC FRAME, P COATED PRO TEC ALL COIL ASM 4PK (FLAT END COIL) ALL COIL CAP (FLAT END COIL) NO HOLE ALL 8' SECTION OF INSUL BLKT(BN053) CUT x (5) 1 ALL INSULATION DISC RETAINER 17.5DIA ALL INSUL BLKT 5OSQ’1/2X24 8# 25' ALL COIL WRAP (FLAT END COIL) BOTTOM ALL COIL, 4PK SCH 80 18 " ALL COIL WRAP (FALT END COIL) TOP ALL BURNER RAIN GUARD-HP-2004 ALL END CAP (FLAT END COIL) 18IN BU W/HOLE ALL BURNER NIPPLE, 1/2 x 5 SCH80 ALL COIL NIPPLE RETAINER 1/2in ALL INSUL DISC RETAINER 17.5DIA W/HOLE ALL FUEL NOZZLE 2.5 80B SC30004VH FUEL NOZZLE 3.00 90B SC30005VH FUEL NOZZLE 3.25 90B SC35006VG FUEL NOZZLE 3.5 90B SC35006KG FUEL PUMP, BECKETT SM/BU600 ALL FUEL FILTER; INLINE ALL BURNER; BECKETT SM 110V ALL BURNER MOTOR, BECKETT SM 110V ALL STRAIN RELIEF 1/2 HEYCO (3/8) ALL IGN TRANS, BECKETT 110VAC SM ALL SC30004VH, PRESSURE RELIEF 3700psi, black SC30005VH SC35006VG, PRESSURE RELIEF 4500+15% , red SC35006KG STREET ELL 3/8 SC30004VH BRANCH TEE 3/8 STEEL SC30004VH FLOW SWITCH 8 @ 4200 ST5 SC30004VH REED SWITCH FOR(AP500) SC30004VH STREET ELL 1/2F X 3/8M STEEL ALL HOSE 3/8 x 34IN 4000psi NO WIP ALL SC30005VH, SC35006VG, SC35006KG TEE 3/8 STEEL " BURST DISC 8000psi ALL ADAPTER FITTING-BURST DISC ALL PLUG 3/8 FLUSH HEAD HEX STEEL ALL HEX MANIFOLD OUTLET 1/2 X 1/2 X 3/8 X1/2 ALL SWIVEL 3/8F X 1/2M STEEL ALL BARB; HOSE 1/4 BRASS ALL STREET ELL 3/8 ALL HEX NUT 3/8 BRASS-REMOTE UNLOADER ALL SWIVEL 3/8F X 3/8M 90 BRAZED SC30004VH SC30005VH, SC35006VG, SC35006KG SWIVEL 3/8F X 3/8F 90 STEEL UNLOADER 4200PSI 8GPM AR SC30004VH SC30005VH, UNLOADER 3-5 @ 3000 K7-1 SC35006VG UNLOADER K7-2 W/BYPASS #1 SC35006KG HOSE BARB 1/2H X 3/8 BRASS ALL SWIVEL 3/8 STEEL ALL PLUG 3/8 BRASS SC30004VH SC30005VH, SC35006VG, SC35006KG PRESSURE SWITCH 4000 PA/PR16] HOSE, 1/2 LO PRESS BLACK ALL FUEL TANK ADAPTER W/PLASTIC TUBE ALL FUEL TANK 7.5 GAS RED ALL FUEL CAP, GASOLINE ALL FUEL CAP, DIESEL ALL FUEL TANK 18 DIESEL CLEAR ALL FUEL TANK BUSHING 1/4 ALL FUEL TANK ELL 1/4 ALL SWIVEL 3/8F X 3/8M 90 ALL NIPPLE 1/2 BRASS ALL HOSE BARB 1/2 BRASS ALL TEE 1/2 BRASS ALL SCREEN WASHER GARDEN H A ALL GARDEN H A 3in LONG 1/2 NPT ALL SC35006VG, REINFORCEMENT BRACKET-PUMP RAIL SC35006KG SC30004VH, PUMP [email protected] & [email protected] RIGHT HAND SC30005VH SC35006VG, PUMP 5.6/3500 NICKEL PLATED SC35006KG 72 HPR60 73 HPR61 74 HPR07 HPR10 75 MB050 76 MB020 77 MB025 78 HS033 PUMP RAIL BOLT PUMP RAIL BOLT,EXTENDED LENGTH PUMP MOUNTING RAIL STAINLESS PUMP ANGLE RAIL AR 4000 SC GENERATOR & GUARD ASSEMBLY GENERATOR 2500w LSA321L10 CAPACITOR, MB020 GENERATOR SC GEN BELT GUARD 80 KT040 SHEAVE BK40H KT047 SHEAVE BK47H 81 KV038 SHEAVE 3TB38 KV046 SHEAVE 3TB46 82 KU100 KU090 83 KSH19 85 KSP16 86 KSA30 KSA32 KSA33 87 KSB42 SHEAVE 2BK100H SHEAVE 2BK90H BUSHING H24MM BUSHING P1 X 1 BELT 5L230 BELT 5L250 BELT 5L240 BELT BX42 KSB4X BELT BX40 88 HS036 HSC54 90 MS145 MS150 MS210 MK200 93 MS006 95 HS021 HS074 HS022 100 HSC24 SC PUMP BELT GUARD 16HP VAN SC PUMP BELT GUARD KOHLER 25HP ENGINE 14 HP VANGUARD E/S ENGINE GAS 16HP VANGUARD E/S ENGINE GAS 21HP VANGUARD E/S ENGINE 20 HP KOHLER CS W/MUFFL OIL DRAIN VALVE 3/8 VANGUARD MUFF/BURNER HEAT SHIELD KOHLER MUFF/BURNER HEAT SHIELD KOHLER MUFF/BURNER HEAT SHIELD NEW 12/00 CONTROL PANEL SC KEY SWITCH/CHOKE/ LIGHT HOLES LABEL HYDRO TEK 34 x 3 *** HOT MOBILE SKID NOZZLE/QDC 045 x 0 ALL ALL SC35006VG, SC35006KG SC30004VH,SC30005VH ALL ALL ALL ALL SC30004VH, SC35006VG, SC35006KG SC30005VH SC30004VH, SC35006VG, SC35006KG SC30005VH SC30004VH, SC35006VG, SC35006KG SC30005VH ALL ALL SC30004VH, SC35006VG SC30005VH SC35006KG SC30004VH SC30005VH, SC35006VG, SC35006KG SC30004VH, SC30005VH, SC35006VG SC35006KG SC30004VH SC30005VH SC35006VG SC35006KG ALL SC30004VH, SC30005VH SC35006VG SC35006KG ALL ALL SC30004VH SC30005VH, SC35006VG, NQ550 NOZZLE/QDC 055 x 0 SC35006KG 105 NQ452 NOZZLE/QDC 045 x 15 SC30004VH SC30005VH, SC35006VG, NQ552 NOZZLE/QDC 055 x 15 SC35006KG 106 NQ454 NOZZLE/QDC 045 x 40 SC30004VH SC30005VH, SC35006VG, NQ554 NOZZLE/QDC 055 x 40 SC35006KG 107 HLB09 GROMET NOZZLE HOLDER ALL 110 GLL10 LABEL GASOLINE ONLY ALL 111 GLL20 LABEL DIESEL FUEL ONLY ALL 113 EP154 GFCI DUPLEX RECEPTACLE 20 AMP ALL 115 HSC51 LASER CUT SC BOX ASM/TOP AND BOTTOM ALL 116 ECH70 KNOB, BLUE .25 X 1.5OD ALL 117 EC410 ROCKER SWITCH 110V RED SPST ALL 118 ECH55 THERMOSTAT,60-190F ALL 119 ECF10 CIRCUT BREAKER 15 AMP ALL 120 GLL57 LABEL,SC/SS PANEL CONTOL BOX ALL 121 HB100 BATTERY BOX ATTWOOD G24 (LARGE) ALL 123 GLL30 MAINTENANCE LABEL 4x4 SC,SS,SM ALL 125 VG200 GUN VALVE 12 @ 4000 ST1500 ALL 126 VW045 WAND 1/4 x 48in MOLDED GRIP ALL 127 DQ04S COUPLER 1/4 SOCK FEM ALL 128 DH050 HOSE 3/8 x 50' 3000psi 250F BL SC30004VH, SC30005VH DH057 HOSE 3/8 x 50' 4000psi BLK/RED SC35006VG, SC35006KG 130 HB025 LARGE BATTERY BOX TRAY 12-03 NEW ALL 131 DQ74T M22 TWIST COUPLER 1/4 MALE " ALL 132 DQ74F TWIST COUPLER 1/4 PLUG FEM-SUT " ALL 133 HNZ05 NOZZLE HOLDER (FOR WAND) ALL 132 HLB30 GROMET; WAND 1 " ALL WAND ASSEM 48 MOLDED GRIP W/NOZZLE 135 AVGH3 HOLDER " ALL PHK40 VALVE KIT FOR PH411 SC30004VH, SC30005VH PHK30 PACKING KIT HYDROTEK [email protected] SC30004VH, SC30005VH PGK01 VALVE KIT ; (6) GP K01 SC35006VG, SC35006KG KIT 69; PACKING REPLACEMENT K69 SC35006VG, SC35006KG 103 GLL79 104 NQ450 Aussie Hydro-Loop System … Operation & Maintenance Manual 23 Australian Pump Industries SC 12V DIESEL EXPLODED VIEW 24 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SC 12V DIESEL PARTS LIST (Jan 09 effective s/n 200900108) FRAME-SC STAINLESS-OPTION-2008 1 HSC71 PROTECT IT SC FRAME DIESEL; P COATED PROTECTIT HSC63 FRAME-2008 2 MU168 ENGINE, KUBOTA 16.8 HP ZINC ENGINE MOUNT LEFT 16 HP NEW FOR 3 HS228 Z602 KUBOTA 4 KSB38 BELT BX38 KSB4X 5 KSH19 6 KSP18 7 KV038 8 KU100 9 HSC61 10 MU222 BELT BX40 BUSHING H24MM BUSHING P1 x 1 1/8 " SHEAVE 3TB38 SHEAVE 2BK100H SC PUMP BELT GUARD KOHLER 18HP PULLEY GUARD 17HP KUBOTA FLYWHEEL GUARD 12.5 HP KUBOTA 11 MU212 SC30006D12 12 DHR75 RADIATOR HOSE 1 1/4 EXTENDED " 13 PG563 PH407 14 HPR07 15 HPR60 16 FB641 17 D2088 18 DE866 19 D8128 20 D6788 21 UPT46 22 D5588 23 D8088 24 VVB10 25 MU155 26 BU013 27 BZ225 28 BM514 29 ECC07 30 EWC08 31 D8044 32 D2044 33 BF020 34 D8040 35 HS229 36 HRR07 37 B0029 38 BN053 39 BN125 40 BN053 41 B0089 42 BC480 43 B0088 44 BN126 45 B0017 46 BC225 47 HHP15 48 B2324 49 BC850 50 HHA00 51 DE568 52 D1061 53 UPB05 54 UPB80 55 DE586 56 DE066 57 UP137 UP045 58 WT078 59 WT080 SC30006D12 SC35006D12,S C40006D12 ALL ALL SC30006D12 SC35006D12,S C40006D12 ALL ALL ALL ALL ALL ALL ALL ALL SC30006D12,S PUMP 5.6 @ 3500 NICKEL PLATED MANIFOLD C35006D12 PUMP [email protected] & [email protected] DUAL SC40006D12 PUMP MOUNTING RAIL-GENERAL/AR 12 GA SS ALL PUMP RAIL BOLT ALL BOLT 3/8 x 2 1/2" PLD ALLTHREAD " ALL NIPPLE 1/2 BRASS " ALL SWIVEL 3/8F x 3/8"M 90 " ALL HOSE BARB 3/4H x 1/2"P BRASS " ALL CROSS 1/2 BRASS-not potted " ALL THERM DUMP VALVE 145f 1/2MPT " ALL ELBOW; STREET; 1/2 BRASS " ALL HOSE BARB 1/2 BRASS " ALL GATE VALVE 1 1/2 PVC " SC30006D12 COOLANT RECOVERY TANK ALL BURNER; BECKETT 12V W/ SUPPORTED FLANGE ALL FUEL NOZZEL 2.25 80B ALL BURNER MOTOR 12V BECKETT ALL RELAY; BURNER; 12V DC ( CAN TYP ALL STRAIN RELIEF 1/2 HEYCO " ALL BARB; HOSE; 1/4 BRASS .312t " ALL NIPPLE 1/4 BRASS " ALL FUEL FILTER RACOR HYDRO TEK ALL HOSE BARB 1/4 90 ELBOW " ALL ZINC ENGINE MOUNT RIGHT 16 HP NEW FOR Z602 KUBOTA ALL SUPPORT BRKT-PUMP RAIL ALL COIL CAP (FLAT END COIL) NO HOLE ALL 8' SECTION OF INSUL BLKT(BN053) CUT x (5) 17.5 DIA ALL INSULATION DISC RETAINER 17.5 DIA ALL INSUL BLKT50SQ 1/2 x 24 8# 25' ALL COIL WRAP (FLAT END COIL) TOP ALL COIL 4PK SCH 80 ALL COIL WRAP (FLAT END COIL) BOTTOM ALL INSUL DISC RETAINER 17.5 DIA W/HOLE ALL END CAP (FLAT END COIL) 18IN BURNER ALL COIL ASM 4PK (FLAT END COIL) 5/01 ALL BURNER RAIN GUARD-HP-2004 ALL COIL NIPPLE RETAINER 1/2in ALL BURNER NIPPLE 1/2 x 5' SCH 80 " ALL HEX MANI OUTLET 1/2 x 1/2" NO REEL " ALL SWIVEL 3/8F x 1/2"M STEEL " ALL PLUG 3/8 FLUSH HEAD HEX SOCKET " ALL ADAPTER FITTING-BURST DISC ALL BURST DISC 8000psi TORQUE 32-4 ALL STREET ELL 1/2F x 3/8"M STEEL " ALL TEE 3/8 STEEL " ALL PRESSURE RELIEF 3700psi black SC30006D12 SC35006D12,S PRESSURE RELIEF 4500+15% 500q C40006D12 FUEL TANK 18 GA DIESEL CLEAR* ALL FUEL CAP; DIESEL ALL 60 DFF04 61 DFE04 62 FC084 63 UU371 UU323 64 DE766 DE866 65 DH034 FUEL TANK BUSHING 1/4 " FUEL TANK ELL 1/4 " WORMGEAR CLAMP 2 1/2 x 20 UNLOADER 3-5 @ 3500 K7-1 UNLOADER 4350psi 8GPM AR SWIVEL 3/8F x 90 STEEL (BRAZED) " SWIVEL 3/8F x 3/8M 90 BRAZED HOSE 3/8 x 34" 5000psi NO WIP " ALL ALL ALL SC30006D12,SC35006D12 SC40006D12 SC30006D12,SC35006D12 SC40006D12 ALL 66 VS030 PRESURE SWITCH 4000 1/4 PR16 " 67 D8068 HOSE BARB 1/2H x 3/8"P BRASS " ALL ALL 68 DE566 SWIVEL 3/8 STEEL " 69 DHC80 HOSE; 1/2 LO PRESS BLACK " ALL ALL 70 D7061 71 DC568 72 D3120 73 VF125 74 D8120 75 D0020 76 D008M 77 D7080 78 D1128 79 HB100 80 HB026 81 DA046 82 HSS51 83 GLL57 84 EM305 85 ECH72 86 EC405 87 ECF15 88 ECH55 89 ESC12 ALL ALL SC30006D12 SC30006D12 SC30006D12 ALL ALL SC30006D12 SC30006D12 ALL ALL SC40006D12 ALL ALL ALL ALL ALL ALL ALL ALL HEX NUT 3/8 BRASS-REMOTE UNLOADER " STREET ELL 3/8 STEEL " COUPLING 3/4 POLY " FILTER 3/4 Y TYPE 80 MICRON/20 " HOSE BARB 3/4 BRASS* " WASHER GARDEN H A GARDEN H A 1/2 NPT MALE " LOCKNUT 1/2 BRASS NPT " BUSHING 3/4 x 1/2" BRASS " BATTERY BOX ATTWOOD G24 (LARGE) LARGE BATTERY BOX TRAY BUSHING 3/8 x 1/4 STEEL LASER CUT BOX ASM LABEL; SC/SS PANEL CONTROL BOX** HOUR METER 12 VOLT DC KNOB; RED .25id x 1.5od ROCKER SWITCH CLR 12V 20A DPST CIRCUIT BREAKER 20 AMP8 THERMOSTAT; 60-190F*** ELEC BOX 12V DC SC30006D12 CONTROL PANEL SC30006D12 KEY SWITCH/ 90 HSC24 CHOKE/LIGHT ALL 91 DH026 HOSE 3/8 x 26.5 4000psi SC30006D12 DH032 HOSE 3/8 x 30IN 4000psi NO WIP LABEL PRO MOBILE WASH SKID 3.00 x 92 GLL97 21.125 SC35006D12,SC40006D12 93 HLB09 GROMET NOZZLE HOLDER 94 NQ600 NOZZLE/QDC 06 x 0 ALL SC30006D12 NQ550 NQ500 95 NQ602 NQ552 NQ502 96 NQ604 NQ554 NQ504 97 ESC17 99 MU262 100 GLL30 101 GLL20 102 VG200 103 DQ74T 104 DQ74F 105 HLB30 106 HNZ05 107 VW045 108 DQ04S 109 AVGH3 110 DH050 DH057 ABMAG PGK02 PGK21 K69 PGK01 PHK64 PHK58 ALL NOZZLE/QDC 055 x 0* SC35006D12 NOZZLE/QDC 05 x 0 SC40006D12 NOZZLE/QDC 06 x 15 SC30006D12 NOZZLE/QDC 055 x 15* SC35006D12 NOZZLE/QDC 05 x 15 SC40006D12 NOZZLE/QDC 06 x 40 SC30006D12 NOZZLE/QDC 055 x 40 SC35006D12 NOZZLE/QDC 05 x 40 SC40006D12 KEY SWITCH HARNESS KUBOTA-17 HP ALL INDICATOR LAMP: KOBOTA ALL MAINTENANCE LABEL 4 x 4 SC,SS ALL LABEL DIESEL FUEL ONLY ALL TRIGGER GUN INSULATED 4000psi ALL M22 TWIST COUPLR 1/4 MALE " ALL TWIST COUPLER 1/4 PLUG FEM-SUT " ALL GROMET; WAND 1 " ALL NOZZLE HOLDER (FOR WAND) ALL WAND 1/4 x 48" MOLDED GRIP " ALL COUPLER 1/4 SOCK FEM " ALL WAND ASSEM 48 MOLDED GRIP W/NOZZLE HOLDER " ALL HOSE 3/8 x 50' 3000psi 250F BL " SC30006D12 HOSE 3/8 x 50' 4000psi BLK/RED SC35006D12,SC40006D12 OPERATION PACKET HYDRO PRO ALL OIL SEAL KIT FOR PG563 GENERAL PUMP (1) REQUIRED PLUNGER FOR PG563 GENERAL PUMP (3) REQUIRED SEAL KIT FOR PG563 GENERAL PUMP (1) REQUIRED VALVE KIT FOR PG563 GENERAL PUMP (1) REQUIRED VALVE KIT FOR PH407 AR PUMP SEAL KIT FOR PH407 AR PUMP Aussie Hydro-Loop System … Operation & Maintenance Manual 25 Australian Pump Industries SS EXPLODED VIEW 26 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries SS PARTS LIST (Feb 09 effective s/n 200900240) 1 HSS00 2 MH009 MH135 MS145 MS150 3 MKD13 4 MS006 5 HSS17 HSS05 6 PG303 PG404 P4060 7 DE866 8 D6588 9 D5588 10 D8088 11 D009M 12 D0021 13 D8044 14 D2088 15 D008F 16 DE766 17 D1040 18 UPT46 19 DA064 20 DC043 21 VS030 22 DEB66 23 VA010 24 UP045 25 MH225 26 B0029 27 BN053 28 BN125 29 B0089 30 BC480 31 B0088 32 BN126 33 B0017 34 BC850 35 BC225 36 HHP15 37 B2324 38 DE586 39 DE066 40 UP137 UP045 41 VS005 42 DEB66 43 HHA00 44 ECH75 45 UPB05 46 UPB80 47 DE568 48 BZ175 BZ225 BZ226 49 ECC07 50 EWC08 51 BU013 52 D8044 53 BF015 54 UU370 UU323 FRAME STACKABLE B/D SS ASSEM ENGINE 9hp HONDA PULL START ENGINE 13hp HONDA E/S 18amp*** ENGINE 14hp VANGUARD E/S ENGINE GAS 16hp VANGUARD E/S W OIL DRAIN ADAPTER 12mm x 3/8 " OIL DRAIN VALVE 3/8 SS EXAUST/FUEL TANK SHIELD VAN MUFF/HEAT SHIELD LEFT #1 PUMP [email protected] W/UNL/INJ 1 GAS " PUMP [email protected]; GENERAL 1 DD PUMP 66DX40G1I 4000 @ 4 SHAFT ALL SS30003HG SS32004HG SS38004VG SS40004VC SS30003HG,SS32004HG ALL SS30003HG,SS32004HG SS38004VG,SS40004VC SS30003HG SS32004HG,SS38004VG SS40004VC SS32004HG,SS38004VG, SWIVEL 3/8F x 3/8M 90 SS40004VC SS32004HG,SS38004VG, STREET TEE 1/2 BRASS SS40004VC SS30003HG,SS32004HG, ELBOW, STREET 1/2 BRASS " SS38004VG,SS40004VC SS32004HG,SS38004VG, HOSE BARB 1/2 BRASS SS40004VC GARDEN H A 3in LONG 1/2 NPT SS30003HG,SS40004VC SCREEN WASHER GARDEN H A ALL BARB, HOSE 1/4 BRASS " SS40004VC NIPPLE 1/2 BRASS SS32004HG,SS38004VG GARDEN H A 1/2 NPT FEM SS32004HG,SS38004VG SWIVEL 3/8F x 90 STEEL SS30003HG PLUG 1/4 BRASS SS30003HG THERM DUMP VALVE 145f 1/2MPT ALL BUSHING 3/8 x 1/4 STEEL SS30003HG STREET ELL 1/4, STEEL SS30003HG PRESSURE SWITCH 4000 1/4 PR16 " ALL BRANCH TEE 3/8 STEEL SS40004VC EZ START VALVE SS40004VC PRESSURE RELIEF 4500+15% 500q SS40004VC HONDA VOLTAGE REGULATOR GX270 SS30003HG,SS32004HG COIL CAP (FLAT END COIL) NO HOLE ALL INSUL BLKT 50sq' 1/2 x 24 8# 25' ALL INSUL DISC RETAINER 17.5DIA ALL COIL WRAP (FLAT END COIL) TOP ALL COIL, 4PK SCH 80 ALL COIL WRAP (FLAT END COIL) BOTTOM ALL INSUL DISC RETAINER 17.5 DIA. W/ HOLE ALL END CAP (FLAT END COIL) 18in BURNER ALL BURNER NIPPLE; 1/2 x 5 SCH80 ALL COIL ASM 4PK (FLAT END COIL) ALL BURNER RAINGUARD-HP-2004 ALL COIL NIPPLE RETAINER 1/2in ALL STREET ELL 1/2F x 3/8M STEEL ALL SS32004HG,SS38004VG, TEE 3/8 STEEL SS40004VC PRESSURE RELIEF 3700psi black SS30003HG,SS32004HG PRESSURE RELIEF 4500+15% 500q SS38004VG,SS40004VC FLOW SWITCH 8 @ 4200 ST5 SS30003HG BRANCH TEE 3/8 STEEL SS30003HG HEX MANI OUTLET 1/2 x 1/2 NO REEL ALL HEAVY DUTY BEND RESTRICTOR -B ALL ADAPTER FITING-BURST DISC*** ALL BURST DISC 8000psi TORQUE 32-4 ALL SWIVEL 3/8F x 1/2M STEEL ALL FUEL NOZZLE 1.75 80B SS30003HG FUEL NOZZLE 2.25 80B SS32004HG,SS38004VG FUEL NOZZLE 2.25 80A SS40004VC RELAY; BURNER 12V DC (CAN TYPE) ALL STRAIN RELIEF 1/2 HEYCO (3/8) ALL BURNER; BECKET 12V W/SUPPORT ALL BARB; HOSE 1/4 BRASS* .312 t ALL FUEL FILTER; INLINE ALL UNLOADER 2-4 @ 3200 K7-0 SS32004HG UNLOADER 4350si 8GPM AR SS38004VG,SS40004VC 57 DE766 SWIVEL 3/8F x 90 STEEL (BRAZED) ALL SS32004HG,SS38004VG,SS4 0004VC ALL ALL SS38004VG,SS40004VC SS32004HG,SS38004VG,SS4 62 DE566 SWIVEL 3/8 STEEL 0004VC HEX NUT 3/8 BRASS-REMOTE SS32004HG,SS38004VG,SS4 63 D7061 UNLOADER 0004VC SS32004HG,SS38004VG,SS4 64 DC568 STREET ELL 3/8 STEEL 0004VC SS32004HG,SS38004VG,SS4 65 DH026 HOSE 3/8 x 30in 5000psi NO WIP 0004VC 66 DH003 HOSE 3/8 x 18in 5000psi SS30003HG SS32004HG,SS38004VG,SS4 DH032 HOSE 3/8 x 30in 5000psi NO WIP 0004VC 67 HB100 BATTERY BOX ATTWOOD G24 (LARGE) ALL 68 HB025 LARGE BATTERY BOX TRAY SS38004VG 69 WT07R FUEL TANK 7.5 GAS RED SS38004VG,SS40004VC 70 WT081 FUEL CAP; GASOLINE SS38004VG,SS40004VC 71 DFF04 FUEL TANK BUSHING 1/4 ALL 72 DF599 FUEL TANK ADAPTER W/PLASTIC TUBE SS38004VG,SS40004VC 73 WT075 FUEL TANK 7.5 DIESEL CLEAR* ALL 74 WT080 FUEL CAP; DIESEL ALL 75 DFE04 FUEL TANK ELL 1/4 ALL 76 HSS12 SS CONTROL PANEL-SS32004HH 37186 SS30003HG,SS32004HG HSS03 SS PROLINECON PANEL NO RADIUS SS38004VG,SS40004VC LABEL HYDRO TEK 34 x 3*** HOT 78 GLL79 MOBILE SKID ALL 79 GLL10 LABEL GASOLINE ONLY ALL 80 GLL20 LABEL DIESEL FUEL ONLY ALL 81 HLB09 GROMET NOZZLE HOLDER*** ALL 82 NQ350 NOZZLE/QDC 035 x 0 SS30003HG NQ450 NOZZLE/QDC 045 x 0 SS32004HG NQ400 NOZZLE/QDC 04 x 0 SS38004VG,SS40004VC 83 NQ352 NOZZLE/QDC 035 x 15 SS30003HG NQ452 NOZZLE/QDC 045 x 15 SS32004HG NQ402 NOZZLE/QDC 04 x 15 SS38004VG,SS40004VC 84 NQ253 NOZZLE/QDC 025 x 25 SS30003HG NQ353 NOZZLE/QDC 035 x 25 SS32004HG NQ303 NOZZLE/QDC 03 x 25 SS38004VG,SS40004VC 85 NQ970 NOZZLE/QDC 40.0 x 65 ALL 86 EC405 ROCKER SWITCH CLR 12V 20A DPST ALL 87 ECH72 KNOB; RED .25 x 1.50od ALL 88 ECH50 THERMASTAT; 60-260 1 GP PART=25 ALL TANK, FLOAT 4 GAL HD LINEAR (NO 89 WT040 HOLES) OPTIONAL FOR SS40004VC 90 VVF08 FLOAT VALVE 3/8 BRASS OPTIONAL FOR SS40004VC 91 HL017 TANK CAP 4in W/HOLE OPTIONAL FOR SS40004VC 92 D5566 STREET ELL 3/8 BRASS OPTIONAL FOR SS40004VC 93 D7520 PANEL FITTING 3/4 BRASS OPTIONAL FOR SS40004VC 94 FW701 FLOAT TANK WASHER 1.75od 14GA SS OPTIONAL FOR SS40004VC 95 D0010 SPRING GARDEN H A OPTIONAL FOR SS40004VC 96 D006M GARDEN H A 3/8 NPT MALE OPTIONAL FOR SS40004VC 97 D0021 SCREEN WASHER GARDEN H A OPTIONAL FOR SS40004VC 98 DFF10 WATER TANK BUSHING OPTIONAL FOR SS40004VC 99 VF050 STRAINER TUBE FOR FLOAT TANK OPTIONAL FOR SS40004VC 100 D1010 SPLICER 5/8 BRASS OPTIONAL FOR SS40004VC 101 HSS20 FLOAT TANK SPACER (SS SERIES) OPTIONAL FOR SS40004VC 102 WT046 FLOAT TANK ASM W/VALVE/FILTER OPTIONAL FOR SS40004VC 103 VG200 TRIGGER GUN, INSULATED 4000psi ALL 104 DQ74T M22 TWIST COUPLER 1/4 MALE " ALL 105 DQ74F TWIST COUPLER 1/4 PLUG FEM-sut " ALL 106 HNZ05 NOZZLE HOLDER (FOR WAND) ALL 107 HLB30 GROMET; WAND 1 " ALL 108 VW045 WAND 1/4 x 48in MOLDED GRIP ALL 109 DQ04S COUPLER 1/4 SOCK FEM ALL WAND ASSEM 48 MOLDED GRIP W/ 110 AVGH3 NOZZLE HOLDER " ALL 111 DH050 HOSE 3/8 x 50' 3000psi 250f BL DH057 HOSE 3/8 x 50' 4000psi 250f re ABMAG OPERATION PACKET GENERAL PRO 58 VC037 59 DHB04 60 VF042 61 DA064 CHEMICAL INJECTOR ADJ. 4000psi TUBING; CLEAR BRAIDED; 1/4 STRAINER CHEM (NO CHECK) BUSHING 3/8M x 1/4 STEEL Aussie Hydro-Loop System … Operation & Maintenance Manual 27 Australian Pump Industries WASTE WATER RECOVERY UNIT Protecting the environment from wash water runoff and complying with governmental storm drain regulations is simple, economical and effective with the AZV55 when cleaning concrete on driveways, floors and parking lots. Wash water is trapped and filtered through 7 stages with reduction to 5 microns and stored in your trailer tank for repeated use by the pressure washer. The unit is equipped with 2 large capacity pleated filters. No outside power supply is required and with an almost unlimited reusable water supply it is the ultimate in conservation. THE MODEL AZV55 IS PROVIDED WITH A DAMMING SYSTEM AND GROUND PICK UP SCUPPER WITH VACUUM HOSE FOR WATER COLLECTION AND PICK UP SUCTION TO THE SYSTEM FOR PROCESSING AND STORAGE FOR RE-USE. Minimum Requirements 115 volt 2.9kw generator, 12 volt 15 amp engine charging system and 12 volt battery. 600 litre bulk supply tank Specially designed trailer hose reels available Drain all tanks and replace cartridges daily, use Hydrotek replacements or exact equivalents to avoid damage to the pressure washer. VACUUM SYSTEM VACUUM MOTOR 104CFM, 2 stage motor, 91” lift, recovers 5gpm+ VACUUM POWER 115v/8.6 amp (Powered by SC or SCU Series Generator) BARRIER 2 X 10’ dual water tubes, 2 X 10’ sand dam tubes PICK UP VACUUM HOSE 1 X 1.5” x 50’ spiral vacuum hose SEPARATOR TANK HOPPER polyethylene seamless molded, slant cone bottom, 40 gallon capacity OIL SEPARATAION center water column removal process, single oil skimmer bag 40# capacity SOLIDS SEPARATION gravity separation with 1-1/2” sludge/solids drain MOUNTING seven bolt mounting on rear of Hydrotek trailer FILTRATION 7 stage TRANSFER PUMP 4.9 gpm 45 psi triplex diaphragm with pressure shutoff & automatic level control PUMP POWER 12vdc/13 amp, circuit breaker protected, lighted switch (Powered by SC or SCU battery) INLET FILTER (HVFB41) 1 X Duo Flow dirt bag, mounted inside separator tank FINAL FILTER (HVFB05) 1 X 5 micron polyester felt bag 7” x 32” mounted on lid in storage tank OIL SKIMMER (HVB040) 8” x 24” absorbent skimmer, sludge drain CARTRIDGE FILTER (HVFH07) 1 X 20 micron pleated polyethylene filtering material, 32 sq ft CARBON FILTER (HVFH10) 1 X 10 micron pleated, activated carbon filter, oil and odour removal, 32 sq ft WARRANTY 90 day accessory warranty 28 Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries RECOVERY UNIT OPERATING INSTRUCTIONS Caution – when using the unit as a vacuum recovery unit, ensure the area to be cleaned is thoroughly brushed and swept, to remove debris which may otherwise affect the operation of the vacuum system and block the filters. Caution – ensure the instructions regarding filter cleaning are followed to ensure effective operation of the recovery system. Scupper pick-up Place the sand dam and water dike system at the low area to create a seal to capture wash water runoff. Install the vacuum hose provided between the scupper pick-up device and the inlet to the filtration system. Have extra duo flow dirt bags readily available, as it is quicker to change the bag when they get dirty during a job. After the job, clean all used filter bags for reuse. Start engine on the Hydrotek pressure washer and turn on auxiliary power switch (if equipped) Turn on vacuum motor switch. Turn on transfer pump switch. Switches must remain in the “ON” position while working. When washing and recovery is completed, shut off vacuum system prior to turning off Hydrotek unit. Vacuum system power switch Transfer pump power switch Turn off switch for transfer pump system after transfer pump completes pump out cycle. Drain hopper into a bucket; replace oil skimmer absorber as required, dispose of sludge properly at hazardous materials collection center (do not exceed 6” of sludge in hopper). Drain hopper before towing if unit is trailer mounted. Vac hose inlet connection Clean or replace cartridges at consistent 25 psi running pressure. Bag filters can be cleaned and reused until plugged. Clean daily (or every 9 hours of use, whichever is less) Drain water in bulk supply tank daily to prevent bacterial contamination or treat with chlorine. DO NOT drink water! Dispose of grey water properly and with proper permits as required by your local regulations. NOTE: Depending on the dry sweeping clean up done before pressure washing, the inlet filter may have service intervals between 15-20 minutes or as long as 45-60 minutes. Replace carbon filter monthly, or after 40 hours usage as required. Replace or clean cartridge filters daily or more often under severe conditions. (Keep a large supply of replacement filters on hand). Do not use soap or other additives. Note: The AZV systems have a FILTRATION BYPASS/RECOVER MODE ONLY. Simply disconnect fitting at the filter inlet to allow direct discharge to a controller permitted sewer line, landscape area or discharge area (when legally available). Disconnect the hose at the filters, to bypass filters, and attach ¾ garden hose to fitting and route to permitted discharge point. If discharging to sewer, change the Duo Flow Dirt Bag filter to the optional capture strainer bag. Aussie Hydro-Loop System … Operation & Maintenance Manual 29 Australian Pump Industries RECOVERY UNIT TROUBLESHOOTING Submersible pick up pump; , If sump pump is on but will not pump, remove discharge hose and run pump to allow it to prime itself. , To reset timer on sump pump, unplug and restart. , Check auxiliary switch position, if equipped. , Check output voltage at plug receptacle of Hydrotek unit , Check GFCI reset on Hydrotek unit Reduced filter flow; Clean or replace cartridges at consistent 25 psi running pressure Bag filters can be cleaned and reused until blocked. Clean daily (or every 8 hours of use which ever is less). , Replace or clean cartridge filters daily or more often under severe conditions. (Keep a large supply of replacement filters on hand) , , Unit will not pump; Check fuse in fuse holder and replace Check battery connections Check battery charge Check reset breaker at panel , , , , Vacuum won’t come on: Check auxiliary switch position, if equipped. Check output voltage at plug receptacle of Hydrotek system Check GFCI reset on Hydrotek unit , , , Vacuum shuts off Check water level in tank. This unit is equipped with a high level shut off system. If indicator light is off this condition is probably due to blocked filters. Check filters for reduced flow, follow procedures for cleaning filters. , Reduced vacuum pick up: This unit is provided with 15 metres and not recommended for additional hose. Check scupper for blockages Check inlet bag filter, follow procedure for cleaning or replace. , , , COMMON REPLACEMENT PARTS FOR RECOVERY UNIT Part Number Description VFH07 Cartridge, 4.5” x 20” 20 micron VFH10 Cartridge 4.5” x 20” 10 micron carbon VB040 Oil skimmer bag VFB41 Duo flow dirt bag VFB05 Bag filter 7 x 32 - 5 micro VFB8S Capture strainer bag, 800 micron (optional) ASF01 Filter start up pack , completer series of filters MEV15 Vacuum motor 115v AC PS120 Transfer pump 12v DHV20 Vacuum hose 15 metres x 2” ZMAT6 Sand berm 10’ - sand not included ATP75 Vacuum scupper pick up device 12” ZMAT7 Deluxe sand berm 6’ - sand not included ATP40 Hydro vacuum arch, 6’ ground pick device ANTV3 Hydro twister flat surface cleaner 30 Always be armed with an extra carbon filter for improved water quality when recycling. The VFB41 duo-flow dirt bag works as you debris catcher when recovering and processing. Switch to VFB8S strainer bag when capture pump only is used. Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries EXPLODED VIEW & PARTS LIST RZVE1-Vacuum Lid assembly uses MEV15 Vacuum motor, (2) EC420 Pump & Vacuum motor switches. Located on underside of lid HSS24 bag holder, VFB41 Duo Flow dirt bag. It’s quicker to have extra filters cleaned and ready to change out while working. The ANTV3 cleans large flat surfaces fast and recovers waste water at the same time. ZMAT7 Deluxe berm for water retention and recovery using the ATP75. Aussie Hydro-Loop System … Operation & Maintenance Manual 31 Australian Pump Industries TRAILER INFORMATION The loaded mass of your trailer must not exceed: the capacity of the towbar the maximum towing mass specified by the tow vehicle's manufacturer the maximum ball weight specified by the tow vehicle's manufacturer Do not overload your trailer. You should not exceed the maximum load specified on the trailer (check plate on drawbar). The ball mass (the weight carried by the tow ball) should be about 10% of total laden trailer weight. This can be measured by placing jockey wheel only on scales. The trailer’s drawbar should be level when being towed. Vehicle handling and braking may be affected if ball weight is too heavy causing the back of the towing vehicle to dip. Regular maintenance of the trailer is essential for safe towing. Have it checked regularly to ensure it is in a safe and roadworthy condition. The trailer's wheel-bearings, suspension and brakes must all be in good working order and tyres must be properly inflated. If attaching items to the rear, do not overload as the balance and towability of the trailer could be adversely affected. Also, make sure you do not obscure the number plate or lighting. Before you tow…. , Inspect all tyres carefully and ensure they are suitably inflated. Remember, when towing heavily loaded trailers your tow vehicle's tyre pressures should be increased to the level recommended in the owner's handbook or on the tyre placard. , Check the trailers wheel nuts have been tightened to the manufacturer's specifications. To tighten the nuts, use a torque wrench to the torque recommended by the manufacturer (around 90ft lb or 125Nm). Wheel nuts should then be retightened after each 100 kms for the first 400 kms and checked every 1,000 kms or at six monthly intervals thereafter or after having your trailer serviced. , Check brakes are correctly adjusted. , Ensure the coupling socket and ball match in size. , Check that the coupling is correctly and securely fastened. , Ensure that your load is properly secured. , Check that the safety chains are correctly connected (D shackle must be suitably rated). , Check that the light connections are secure and that all lights work. , Disengage reversing catch fitted to the trailer coupling (as used with over-run brakes). , Ensure that the hand brake of the trailer has been correctly released. , Make one or two test stops to check that the brakes are working properly. 32 Hand brake off Reversing latch disengaged Aussie Hydro-Loop System … Operation & Maintenance Manual Australian Pump Industries TRAILER INFORMATION , Limit the amount of load in the boot of the tow vehicle. , Ensure that the rear vision mirrors on the tow vehicle are properly adjusted. , Lock the jockey wheel in the travelling position. Reversing trailer … Jockey wheel in travel position , Engage reversing latch before reversing trailer. Damage may result to the trailer if latch is not engaged correctly. , Do not reverse over gutters, kerbs or culverts. These may cause damage to the trailer’s suspension. Once trailer is parked … , Hand brake on Engage hand brake, disconnect electrics and safety chain, and lower jockey wheel before unhitching from tow vehicle. For further information on the trailer please consult the trailer manufacturer. Aussie Hydro-Loop System … Operation & Maintenance Manual 33 Australian Pump Industries Reliable Products … Reliable People 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] 34 Aussie Hydro-Loop System … Operation & Maintenance Manual
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