AUSSIE ECO-CLEAN Monsoon 200 User manual

Aussie Monsoon & Hurricane … Operation & Maintenance Manual 1
Australian Pump Industries
Aussie Eco-Clean
Monsoon Series High Pressure Blaster
(Three Phase Models)
IMPORTANT:
TO REDUCE RISK OF INJURY,
READ OPERATING INSTRUCTIONS
CAREFULLY BEFORE USING EQUIPMENT
Feb 2010
Covers:
Monsoon 200
Monsoon 300
Monsoon 300 Maxi
Monsoon 400
Monsoon 400 Maxi
Hurricane
OPERATION & MAINTENANCE MANUAL

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Australian Pump Industries
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.
WARRANTY COVERAGE
This warranty covers any defect which occurs due to faulty workmanship or material under normal use.
Please keep your receipt as proof of purchase. This warranty specifically excludes the following:
1. Damage resulting from debris or mineral deposits contained within the water supply to the
machine.
2. Leaking hoses when the outer cover of the hose has been abraded or the hose has been kinked.
3. Damage to o-rings and valves, etc. caused by the use of cleaning chemicals or compounds.
4. Replacement of parts damaged due to fair wear and tear.
5. Misuse, negligence, alteration, accident or breakage.
6. Failure of the machine due to lack of normal maintenance services (The owner is responsible for
the performance of regular maintenance services, as specified in the Operator's Manual).
7. Damage and/or progressive damage caused by the failure to inform Australian Pump Industries
Pty Ltd, or the closest Authorised Australian Pump Agent or Distributor, within seven days of the
defect becoming apparent.
8. Repair or modification by an unauthorised service person.
9. Australian Pump Industries Pty Ltd specifically excludes from warranty responsibility any
consequential loss or damage including on-site servicing, loss of time, loss of use of the machine,
hire costs of a replacement machine or inconvenience.
10. Routine maintenance is the owner's responsibility. Failure to maintain the machine in line with
the services outlined on page 8 will invalidate the warranty.
11. Where possible return faulty goods to the place of purchase. No products can be returned to us
without prior permission. The reason for return must be clearly stated.
N.B. Warranty is not transferable 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.
STANDARD EQUIPMENT
Before proceeding with assembly of your new Aussie Eco Clean blaster, check that all parts listed
below are included.
1 Gun handle assembly and high pressure hose
1 Lance and nozzle assembly
1 Inlet hose connector assembly
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.
WARNING:
If pressure drops off, check nozzle for wear. Nozzles should be replaced on a regular basis (every
month for machines in regular use, every 3 months for machines used intermittently. Using the
machine with the incorrect nozzle size or worn nozzle will void warranty and can be dangerous to the
operator.
* * W A R N I N G * *
AUSSIE HEAVY DUTY WATER BLASTERS ARE DESIGNED
FOR PROFESSIONAL OPERATORS ONLY
IMPORTANT
INSTRUCT OPERATORS IN CARE AND USE OF THE MACHINE BEFORE USE!
AUSSIE ECO CLEAN BLASTER OPERATING AND MAINTENANCE INSTRUCTIONS

Aussie Monsoon & Hurricane … Operation & Maintenance Manual 3
Australian Pump Industries
High pressure
hose connection
Supply hose
SAFETY PRECAUTIONS - IMPORTANT
1. NEVER direct the spray jet at any person or animal.
2. NEVER direct spray jet at any surface that may contain asbestos material.
3. NEVER hold a finger over the high pressure nozzle.
4. NEVER direct the spray jet at the machine itself or any electrical equipment.
5. After use release the pressure in the high pressure hose by operating the pistol
trigger.
6. DO NOT attempt any mechanical repair. If you have a problem with your machine
contact your local Aussie Eco Clean Service Division, phone [phone].
7. NEVER supply any liquid other than water to the water inlet.
8. NEVER pull the high pressure hose if it has formed kinks or nooses.
9. NEVER pull the hose over sharp objects.
10. DO NOT attempt to disconnect any hose or coupling with pressure still in the hose.
11. DO NOT operate the machine whilst standing on ladders, use a platform tower or
scaffolding.
12. Children should NOT be allowed to use the machine.
13. We recommend the use of safety goggles when using the machine, particularly
with the sand blasting attachment (optional accessory) or any application where
loose particles of stone or ``grit, etc. may be blown around by the pressure spray.
ASSEMBLY AND PREPARATION FOR USE
1. Check the oil in the pump . Note separate reservoirs. With the
machine on a level surface the oil level should cover the red spot
in the oil level sight glass on the side of the machine. If
necessary, top up with SAE 30w 50 oil (non foaming type). Do
not mix different grades of oil as this may affect the machine=s
performance. If alternative oil is used, first empty out oil by
unscrewing drain plug in bottom of machine.
2. Ensure breather plug is fitted to pump (yellow).
WARNING: Before operation ensure top mounted oil filler plug is
replaced by breather. Failure to fit breather and keep clean can
result in over pressuring of oil chamber (crank case) and can blow oil seals. This will void
warranty..
HEAVY DUTY LANCE: To assemble the lance, insert Section B into Section A and screw together and
check nozzles have been fitted to end of lance (C & D).
HIGH PRESSURE HOSE
Connect the high pressure hose to the threaded water outlet on
the side of the machine via a screw coupling. No spanners are
necessary.
C
D
B
A

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Australian Pump Industries
WATER SUPPLY HOSE:
Use a good quality hose (not supplied) of 25mm diameter minimum.
Fasten the one end of the hose to the inlet hose connector securing using a worm drive clip. This
connection MUST be tight to avoid leaks.
Water supply can be by means of either:
$ Mains Supply
Secure the free end of the hose to your tap using a suitable tap adaptor (not supplied - available
through all good hardware and garden supply stores).
$ Syphon Fed Supply
Place the free end of the hose into a water tank or container and the pump will draw water itself.
Use a larger diameter suction hose, at least 1" diameter and no more than 2 metres long.
Water supply must be above or level with pump.
NOTE: To prevent the ingress of foreign bodies into the pump we recommend that a gauze filter (not
supplied) be fitted to the free end of the hose, before connection to pump.
HOT WATER APPLICATION
Aussie Eco-clean Monsoon & Hurricane water blasters can be used in their standard configuration with
cold or hot water up to 60 C. Using optional Hot Shot seals and valves the pumps can be modified to
operate with water temperatures up to 80 C.
DETERGENT FUNCTION
This machine is designed to handle non-caustic cleaning agents to improve cleaning efficiency.
1. Push clear plastic chemical injection hose with filter assembly onto the injector nipple.
2. Submerge the end of the hose with filter into your chemical container.
3. Reduce pressure of machine to enable venturi system to activate: on double lance
machine adjust by control handle
4. Allow some time for the chemical to work into the grime.
5. Set the lance to high pressure and blast detergent and dirt from the job.
6. Remove pick up hose from detergent bottle.
7. Rinse detergent valve with clean water by running at low pressure.
Warning: leaving detergent in the valve can cause it to stick and malfunction.
OPERATION:
Turn on water supply. Note: Tap should be full on.
Pull the trigger to expel air from the system. Water will trickle from the end of the lance when air is
expelled.
Start the engine. (Refer to engine manual for details)
Check that there are no leaks in the line connections, pistol or power lance. Pressure begins
when the pistol trigger is squeezed. SAFETY … IMPORTANT
EXCESS ATOMISED MOISTURE CAN ENTER SWITCHES &
MOTOR CONNECTIONS AND OVER TIME MAY CAUSE FAILURE
KEEP THE MACHINE OUT OF MOISTURE LADEN ATMOSPHERES
ACCESSORIES: (Consult Selection Guide)
Your Aussie water blaster can be used with a wide variety of optional extras to enhance performance.
To use the accessories you must first disassemble the lance. Unscrew quick coupler to unlock the
lance. The accessories can then be connected to the end of the lance assembly. If quick coupler is
not supplied it can be purchased from your local Aussie Eco-Clean Distributor.

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Australian Pump Industries
A
B
TURBO LANCE - A correctly selected heavy duty turbo lance can cut pressure cleaning time in
half and is a very important accessory.
SANDBLAST HEAD - Wet sandblasting is safe and tremendously effective. Ideal for rust
removal, paint stripping and graffiti removal.
OPTIONAL LANCES - A range of optional lances in stainless steel or zinc plated steel are
available in lengths of up to 2 metres.
ROTARY CLEANER - The Aussie Eco-Clean rotary cleaner allows flat surfaces to be cleaned in
a fraction of the time normally taken. Ideal for contractors and professional users.
LONG LENGTH HOSES - HOSE REELS, COUPLINGS - A wide range of optional long length
hose assemblies, rapid reel hose reels and quick couplers and fittings are available to enhance
your machine=s performance. Consult your Aussie Eco-Clean Distributor for details.
Q STYLE COUPLERS - Colour coded quick couplers make nozzle change over a matter of
seconds. Change from zero degrees for direct impact to 15 or 25 degrees in seconds.
Personal protection apparel recommended.
CARE AND MAINTENANCE:
AFTER EACH USE.....
If cleaning agents have been mixed with the incoming water, it is particularly important to flush the
machine with clean water after use.
If there is a danger of freezing anti-freeze should be mixed with the flush water or the machine must be
completely drained. After the final flush stop the machine. DO NOT allow the machine to idle for more
than 15 seconds. This is particularly important when there is a danger of freezing. Do not run for
longer without water supply.
STORAGE:
Store the washer in an upright position, preferably drained of water if there is a danger of freezing (or fill
with anti-freeze WARNING .... 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 & SUBSEQUENT DAMAGE.
EXCESSIVE BY PASS RUNNING VOIDS WARRANTY!!
ASP SYSTEM..... AUSSIE SAFETY PROTECTOR SYSTEM
THERMAL DUMP (A): All Aussie Eco-clean machines are fitted with
this valve as of June 2000 production. This device protects the pump
by dumping water to ground if the machine is left on bypass running.
AUSSIE SAFETY VALVE (B) OPTIONAL EXTRA: This device
“blows off”excess pressure if unloader has been tampered with thus
protecting the pump. Do not tamper with pre-set unloader and safety
valve. (This will void your warranty.)
AUSSIE FLOW SHUTDOWN DEVICE OPTIONAL EXTRA: a low flow
shutdown device protects the machine from inadequate water supply.
It also has the function of providing a “Total Stop” function be turning
the machine on and off when the operator shuts off the trigger
mechanism.
When the operator turns the gun on again he MUST first switch the double lance back to low pressure,
momentarily, before moving back to the high pressure side of the lance.
The machine will start automatically when the operator presses the gun trigger when the machine is on
low pressure lance adjustment.

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Australian Pump Industries
FAULT
CAUSE REMEDY
Pump running normally
but pressure low on
installation
Pump sucking air
Valves sticking
Unloader valve seat faulty
Nozzle incorrectly sized
Worn piston packing
Check water supply and possibility of air
ingress.
Check and clean or replace if necessary
Check and replace
Check and replace
Check and replace
Fluctuating Pressure Valves worn
Valves blocked
Pump sucking air
Worn piston packing
Check and replace
Check and replace
Check water supply and air ingress at
joints in suction line
Check and replace
Pressure low after period
of normal use
Nozzle worn
Check valves worn
Check valves blocked
Unloader valve seat worn
Worn piston packing
Check and replace
Check and replace
Check and clean
Check and replace
Check and replace
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 and connections on
suction line
Check and replace
Check and clean
Check and replace
Reduce temperature
Presence of water in oil Oil seal worn
High humidity in air
Piston packing worn
Check and replace
Check and change oil twice as often
Check and replace
Water dripping below
pump
Piston packing worn
O.R plunger retainer worn
Check and replace
Check and replace
Oil Dripping Oil seal worn Check and replace if necessary
Valves switches
repeatedly when gun is off
Leaking gun and/or pressure pipe.
Leaky sleeve
Worn out kick-back valve body
Leaky seals
Renew gun, seal pressure pipe
Renew sleeve
Check and renew as necessary kick-
back valve plate and seat
Renew seals
Leaky piston rod Defective O-Ring/Support Ring Renew piston rod seals and examine
surfaces in guide case
Leaky by-pass at nominal
pressure
Nozzle too small, too much water.
Worn out by-pass valve
Install larger nozzle
Examine and renew as necessary,
poppet (16 for APR-11 for VD valves -
10 for ADV-8 for Unifit valves), valve set
(14 or APR-12 for VD valves - 11for
AVD valves - 7 for Unifit) and by-pass
valve body.
Pressure gauge shows
high pressure fluctuations
when shutting off gun
Valve set too high above operating
pressure
Dirty valve
Adjust the unloader at the operating
pressure.
Clean valve (removing lime deposits
etc). Grease parts before installing.
Motor hums when
switched on but does not
start
Main voltage too low
Spray gun not activated
Cross section of extension lead too
small
Check electrical connection
Activate spray gun when switching on
Use correct dimension extension lead
TROUBLE SHOOTING GUIDE

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PARTS IDENTIFICATION
Model Motor Pump Model Pump Pressure
(psi) EWP Flow rate (lpm) Pump rpm
Monsoon 200 7.5HP, 5.5kW, IP56 TTV2015 3000 4785 15 1450
Monsoon 300 10HP, 7.5 kW, IP56 TTV2021 3000 4785 21 1450
Monsoon 300 Maxi 15HP, 10 kW, IP56 KKV2028 3000 4785 28 1450
Monsoon 400 10HP, 7.5 kW, IP56 KTV3015 4000 6400 15 1450
Monsoon 400 Maxi 15HP, 10 kW, IP56 KTV3021 4000 6400 21 1450
Hurricane 17HP,12.5kW, IP56 HDS5057 5000 8500 18 1725
A
B
C
D E
F
G
H
I
J K
L
N
M
Monsoon
Position Part No Description 200 300 300m 400 400m Hurricane
Nozzles
A
C915065M HP NOZZLE (15º ANGLE, TIP SIZE 65) x
C915085M HP NOZZLE (15º ANGLE, TIP SIZE 85) x
C915035M HP NOZZLE (15º ANGLE, TIP SIZE 35) x
C915055M HP NOZZLE (15º ANGLE, TIP SIZE 55) x
C915040M HP NOZZLE (15º ANGLE, TIP SIZE 40) x
B C915500MSS LP DETERGENT NOZZLE x x x x x
Lance & Gun
C C3924.01 684MM SS DUAL LANCE x x x x x
C3905.15 900 MM SS SINGLE LANCE x
D C4326.23 AL5 GUN WITH MELTED HANDLE & QC x x x x x
C4344.12 5000 PSI RATED AL35 GUN & QC x
Hose
E R206K2214MB6X10 10 MTR HP HOSE (R2, 4500 PSI) x x x x x
HW06FB6FB6X10 10 MTR HP HOSE (R2, 5800 PSI) x
Unloader
F C4910.10 UNLOADER VALVE (3600 PSI) x
BVB80/280 UNLOADER VALVE (4000 PSI) x x
BVB350 UNLOADER VALVE (5100 PSI) x x x
Thermal Dump Valves
G MPA60063070 THERMAL DUMP VALVE 1/2" x x x x x x
Inlet Strainer
H AYSTRAINER3/4” 3/4” Y STRAINER x x x x x x
Gauge
I AGCDR0102 6,000 PSI PRESSURE GAUGE x x x x x x
Chemical Injector
J MTM00029143 CHEMICAL INJECTOR x x x x x
Switch
K ASWITCH25A ON/OFF SWITCH (25 AMP) x x x x x x
Electric Motor
M
A140060T001 7.5HP MOTOR (5.5 KW) 24MM x
A140060T002 10HP MOTOR (7.5 KW) 24MM x x
A140060T003 15HP MOTOR (11 KW) 30MM x x
A140060T009 17HP MOTOR (12.5 KW) x
Wheel
N A400016 13" WHEEL x x x x x x
Use motor size & pump model to identify your machine:

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Australian Pump Industries
Kit No. Part No. Description
127 B069872973 Oil Seal & Sight Glass Kit
123 B069867973 Valve Kit
89 B069839973 Seal Kit Minor
86 B069836973 Seal Kit Major
37 B069814973 Oil Seal Kit
Aussie pressure test Aussie pressure test set includes gauge and fitting for testing pump output
PUMP PARTS TTV 2015 2021 (Monsoon 200, 300)

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Kit No. Part No. Description
98 B069842973 Oil seal & Sight Glass kit
40 B069817973 Valve Kit
90 B069840973 Seal Kit Minor
87 B069837973 Seal Kit Major
37 B069813973 Oil Seal Kit
Aussie pressure test Aussie pressure test set includes gauge and fitting for testing pump output
PUMP PARTS KKV 2028 (Monsoon 300 Maxi)

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Australian Pump Industries
PUMP PARTS KTV 3015, 3021 (Monsoon 400, 400 Maxi )
Kit No. Part No. Description
98 B069842973 Oil seal & Sight Glass kit
123 B069867973 Valve Kit
89 B069839973 Seal Kit Minor
86 B069836973 Seal Kit Major
37 B069814973 Oil Seal Kit
Aussie pressure test set Aussie pressure test set includes gauge and fitting for testing pump output pressure and Bertolini Pump Selection Guide

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Australian Pump Industries
PUMP PARTS HDS 5057 (Hurricane)
Kit No. Part No. Description
98 B069842973 Oil seal & Sight Glass kit
95 B069833973 Seal Kit Minor
96 B069834973 Seal Kit Major
37 B069813973 Oil Seal Kit
93 B069829973 Valve Kit
Aussie pressure test set Aussie pressure test set includes gauge and fitting for testing pump output pressure and Bertolini Pump Selection Guide

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Australian Pump Industries
WARNING
OVERSPEEDING
Do not operate machine at over maximum pump rpm. Over speeding can cause serious
pump damage.
EXCESSIVE BYPASS
Do not run on excessive by-pass. Switch machine off within five minutes of ceasing
operation as excessive by-pass can cause heat build up in pump and subsequent
damage. Excessive bypass running voids warranty.
HIGH PRESSURE SETTING
The high pressure pump is factory set to operate at its rated pressure. DO NOT
ADJUST. Tampering with the pressure regulator will void warranty and can be
DANGEROUS.
CHECK NOZZLE MONTHLY
If pressure drops off check nozzle for wear. Nozzles should be replaced on a regular
basis (every month for machines in regular use, every three months for machines used
intermittently). Using the machine with the incorrect nozzle size or worn nozzle will void
warranty and can be DANGEROUS to the operator.
" Check pump oil level
" Check engine oil level
" Check nozzle for wear
" Check all high pressure components for leaks:
" gun/lance
" HP hose
" all fittings
" Check water filter and clean if necessary
" Check unloader, safety valve and thermal dump for leaks
All professional machines need to be thoroughly serviced every three months. The service
involved should include the engine manufacturer's recommendations (see separate Engine
Manual) and the following;
" Change pump oil
" Change gearbox oil (if applicable)
" Check filter for foreign debris
" Check unloader, safety valve and thermal dump for leaks
" Check all HP components for leaks: Gun/lance, HP hose and all fittings
" Replace nozzles
" Check gearbox to engine key for wear, if key is worn see your local Aussie Eco Clean
Service Department
NB Damage generated by worn keys is not covered by warranty!
PRESSURE CLEANER DAILY CHECK LIST
THREE MONTHLY REGULAR SERVICE
Australian Pump Industries Pty Ltd
7 Gladstone Road, Castle Hill NSW 2154
Ph: [phone] Fax: [phone]
www.aussiepumps.com.au [email protected]
WEAR PROTECTIVE GOGGLES
AND CLOTHING!