bar 120 BAR4023CG-HEC 2 User manual

Operator's Manual
Pressure Cleaners –Class B
www.bargroup.com.au
B.A.R. Group Pty Ltd
15 Hudson Place, Mulgrave, NSW 2756
Phone: [phone]; Fax: [phone]
Email: [email protected]
120 BAR4023CG-HEC 2
120 BAR4023CG-HEJM
120 BAR4023CG-HEJMT
120 BAR5027CG-HEJM
120 BAR5027CG-HEJMT
120 BAR5027CG-HEP

PRESSURE CLEANER OPERATOR’S MANUAL
CLASSIFICATION
CLASSIFICATION
High Pressure Water Cleaning systems which include all BAR pressure cleaners are separated into two classes as per
Australian and New Zealand Standard 4233.1 & 2
Class A systems –Produce [pressure*flow] between 800 bar litres per minute and 5600 bar litres per minute.
Class B systems –Produce [pressure*flow] of 5600 bar litres per minute or greater.
A high pressure cleaning system cannot be reclassed by reducing available working pressure, the rating is based on
the units’ maximum output capability.
The following graph provided by Safe Work Australia can assist you to determine the class of your system.
Helpful conversions
Pressure
1
psi =
0.0689
bar
14.5
psi =
1
bar
1000
psi =
68.9
bar
2900
psi =
200
bar
Volume
0.264
gallons =
1
litres
1
gallons =
3.785
litres
2.642
gallons =
10
litres
7.925
gallons =
30
litres
[= 3.14]
Bar litres per minute = pressure (bar) x flow (L/min)
For example –
1000 psi gives 68.9 bar pressure from the conversion table and let’s say we want 60 L/min of flow. So if we follow the
graph, we can see that the lines meet in the green section which is class A and if we put the values into the formula
we get –
68.9 bar x 60 L/min = 4134 bar litres per minute
which justifies the system to be in the class A range as we witnessed from the graph.
Nozzle reaction force (newtons) = 0.182 x pressure (bar) x [x (nozzle diameter / 2)2(mm2)]
[Please refer to online catalogue page - 526 for nozzle diameter.]
This manual references or includes material from the following sources:
Guide for managing risks from high pressure water jetting, Safe Work Australia - https://www.safeworkaustralia.gov.au/
AS/NZS 4233.1:2013 High pressure water jetting systems –Safe operation and maintenance
AS/NZ2 4233.2:2013 High pressure water jetting systems –Construction and performance
This manual is provided as guidance only and does not guarantee compliance with the WHS Act and Regulations in all instances.

PRESSURE CLEANER OPERATOR’S MANUAL
CONTENTS
1
CONTENTS
INTRODUCTION _______________________________________________________2
PRODUCT DETAILS ____________________________________________________2
RISK ASSESSMENT____________________________________________________3
Managing risks___________________________________________________________ 3
Do’s and Don’ts __________________________________________________________ 4
SAFETY ______________________________________________________________5
Precautions______________________________________________________________ 5
Site and Work Area _______________________________________________________ 5
Personal Protective Equipment (PPE) ________________________________________ 5
Hazards and Symbols _____________________________________________________ 6
Medical ________________________________________________________________ 11
Incident reports _________________________________________________________ 11
UNDERSTANDING EQUIPMENT _________________________________________12
120 BAR4023CG-HEC 2 ___________________________________________________ 13
120 BAR4023CG-HEJM ___________________________________________________ 14
120 BAR4023CG-HEJMT __________________________________________________ 15
120 BAR5027CG-HEJM ___________________________________________________ 16
120 BAR5027CG-HEJMT __________________________________________________ 17
120 BAR5027CG-HEP_____________________________________________________ 18
OPERATION _________________________________________________________19
Preparation checks ______________________________________________________ 19
Start-up procedure_______________________________________________________ 20
Shut-down procedure ____________________________________________________ 20
Emergency Stop_________________________________________________________ 20
Safe operation __________________________________________________________ 21
Nozzle selection _________________________________________________________ 21
Equipment inspection ____________________________________________________ 22
PARTS LISTS ________________________________________________________23
120 BAR4023CG-HEC 2 ___________________________________________________ 24
120 BAR4023CG-HEJM ___________________________________________________ 26
120 BAR4023CG-HEJMT __________________________________________________ 28
120 BAR5027CG-HEJM ___________________________________________________ 30
120 BAR5027CG-HEJMT __________________________________________________ 32
120 BAR5027CG-HEP_____________________________________________________ 33
STORAGE ___________________________________________________________36
MAINTENANCE_______________________________________________________36
Records________________________________________________________________ 37
TROUBLESHOOTING__________________________________________________38
TERMS & CONDITIONS ________________________________________________40
Warranty _______________________________________________________________ 40
NOTES______________________________________________________________41

PRESSURE CLEANER OPERATOR’S MANUAL
INTRODUCTION
2
Please check pump oil level through the
sight glass. Make sure it doesn’t fall below
or exceed past the red dot.
INTRODUCTION
Thanks for purchasing a High Pressure Cleaner from BAR Group. Your new equipment is designed to operate at high
pressures for domestic/professional cleaning applications.
This manual is an important part of your pressure cleaner and was written to take you through the safety requirements
and operating functions of your machine. It should be read thoroughly before initial use, and referred to often to ensure
adequate safety and service concerns are being addressed.
Reading the operator’s manual thoroughly will help avoid any personal injury or damage to your machine. By knowing
how best to operate this machine, you will be better positioned to instruct others who may also operate the unit.
You can refer back to the manual at any time to help with understanding procedures or troubleshooting, so store it with
the machine at all times.
PRODUCT DETAILS
If you need to contact an Authorized Dealer or our Customer Service line [phone] for information on servicing,
always provide the product model and serial numbers.
You will need to locate the model and serial number for your machine and record the information in the table provided
below.
Date of Purchase:
Dealer Name:
Dealer Contact:
Product Identification Numbers
Model Number:
Serial Number:
Lubrication Fluids
Engine:
SAE 10W30
Gearbox:
SAE 90
Pump:
Universal Tractor Transmission Oil
Attention: Read through the complete
manual prior to the initial use of your
high pressure water jetter.

PRESSURE CLEANER OPERATOR’S MANUAL
RISK ASSESSMENT
3
RISK ASSESSMENT
Managing risks
Risk is the potential for injury or negative consequence based on the likelihood of a specific event occurring. Controls
must be put in place to eliminate the risk. Where the risk cannot be entirely eliminated, implement controls to reduce
risk by lowering the chance of the event occurring or minimising the severity of the consequence.
The risk matrix below can be used to provide a rank for any specific event.
Likelihood
Consequences
Extreme
Major
Moderate
Minor
Negligible
Certain
25
23
20
16
11
Likely
24
21
17
12
7
Possible
22
18
13
8
4
Unlikely
19
14
9
5
2
Rare
15
10
6
3
1
Some potential hazard events, risk rankings and possible control measures are outlined below.
Potential Hazard
Risk/Consequence
Risk
Ranking
Control measures
High pressure water
jet
Operator injury,
bystander injury
18
Only point jet at area to be cleaned
Use signage and barriers around work area
Stop cleaning if a person enters the work area
Wear appropriate PPE
Never use damaged equipment
Never leave running unit unattended
Unsecured machine
moves during use
Operator injury,
bystander injury
8
Use wheel chocks for mobile units
Periodic checks of mounting fasteners/locking
plates for vehicle mounted units
Uneven ground or
entangled hoses
Operator injury (trip/fall)
8
Clear work area of trip hazards prior to
operating pressure cleaner
Use hose reel to avoid tangle hoses
Wear non-slip footwear
Noise
Hearing damage
11
Use hearing protection when nearby unit
Contact with
chemicals
Skin irritation/burns,
Sight impairment,
Respiratory issues
(fumes)
13
Only use chemical cleaner if absolutely
necessary.
Adequate ventilation for work area
Wear appropriate PPE (gloves, goggles, etc.)
Follow chemical manufacture instructions
High temperature
Operator injury (burns)
9
Avoid hot engine/pump/exhaust components
Appropriate warning labels
Fire or explosion
Operator injury,
bystander injury,
equipment damage
14
Allow engine to cool adequately before
refuelling
Ensure battery terminals are correctly
protected/insulated
Never overcharge battery
Rank
Risk
≥18
Very High
12-17
High
6-11
Medium
≤5
Low

PRESSURE CLEANER OPERATOR’S MANUAL
RISK ASSESSMENT
4
Do’s and Don’ts
DO
Contact site engineer, obtain necessary permits and note special precautions.
Erect barriers, rope off the clear area. Erect warning signs.
Ensure adequate, clean water supply.
Check fluid levels on engine, gearbox and pump. (Oil, fuel and water).
Lay out equipment and visually inspect for damage. (Hoses, connections, etc.)
Assemble equipment checking all joints.
Ensure filters are clean.
Fully prime equipment and bleed where necessary.
Fit gun or lances and/or control valves. Visually check that correct size and type of nozzle is
fitted for the application.
Increase pressure slowly until operating conditions are reached.
Re-check hose couplings and joints for leaks.
Rectify all leaks, ensuring that the unit is shut down and line pressure released before making
adjustments.
Ensure all operators are wearing suitable protective clothing and are correctly positioned.
Regularly check operating conditions. (Oil and water pressure, condition of filters, pipework
and hoses).
Ensure that all pressure in lines is released on any shutdown.
On completion, strip down equipment and store in a clean condition.
Clear the site of barriers, warning signs and debris, to customers' satisfaction.
On completion, ensure that customer has signed the necessary paperwork. (Satisfaction
notes, work sheets, etc.)
DO NOT
DO NOT commence work on site without necessary permission.
DO NOT commence any jetting operation until warning signs are on show and area roped off.
DO NOT operate without adequate personal protection for eyes, head, ears, hands, feet and
body.
DO NOT run any equipment with any leakage whatsoever without rectifying.
DO NOT attempt to tighten any pressure joint whilst equipment is under pressure.
DO NOT by-pass safety cut-outs. Do check reasons for malfunction. (Low water, blocked
filters, low oil level, etc.)
DO NOT operate with guns and control valves not functioning correctly. (Failing to shut off, or
leaking).
DO NOT operate guns or control valves with the operating lever tied back, wedged or locked
in the on position.
DO NOT direct the water jet at any person or animal.
DO NOT direct the water jet towards materials containing asbestos.
DO NOT operate with badly worn or undersized nozzles.
DO NOT continue to operate if any unauthorized personnel enter the operating/work area.
DO NOT operate equipment at power levels which can produce a reaction force greater than
the operator can comfortably absorb. (250N is advised as a maximum)
DO NOT leave unit running unattended.
DO NOT leave equipment unattended on site.
DO NOT store unserviceable equipment. (Notify supervisor.)
DO NOT leave the site in a dangerous or untidy condition.
DO NOT leave site without notifying all parties. (Engineers, site agents, occupiers, etc.)

PRESSURE CLEANER OPERATOR’S MANUAL
SAFETY
5
SAFETY
Precautions
Using a High Pressure Water Cleaner (HPWC) can be very hazardous and all operators must be trained and
competent. Do not operate machine alone, a second operator should always be present.
High pressure water jets can easily penetrate the skin, never place any part of your body in front of the high pressure
nozzle.
Completely drain water from all components if freezing conditions are expected. Ice forming inside pump/hoses can
cause significant personal injury or equipment damage.
Site and Work Area
When working on a construction site, adhere to all signage and ensure correct worksite PPE is worn.
Always assess the site and plan your work prior to set up of the HPWC. Things to consider are:
Potential work area hazards
Potential environmental issues
Appropriate control measures
Safety standards
Emergency procedures
The work area should be adequately ventilated, well lit and free from obstructions. Block off the area using barriers to
keep bystanders and non-essential persons away. Barriers should be erected at a distance outside the effective range
of the high pressure spray so that it is no longer harmful to persons or animals.
Appropriate signage such as “DANGER – HIGH PRESSURE WATER CLEANING EQUIPMENT IN USE” should be
clearly visible to anyone approaching the work area. Nearby workers should be notified of intended operations prior to
commencing works.
Personal Protective Equipment (PPE)
Always wear the appropriate protective equipment.
Good Workplace Health and Safety practices and other risk control measures are not replaced by the use of personal
protective equipment. Preventative measures should always be explored before considering the requirement of PPE.
Where PPE is issued, training in the correct use and maintenance should be provided to all operators and workers.
Head protection
Where required, head protection complying with AS/NZS 1801: 1997: Occupational protective helmets
should be worn.
Eye protection
Eye protection suitable for the task, of good fit on the worker and complying with AS/NZS 1337: 2010
(Series): Personal eye protection should always be worn when the worker is near jetting operations. The
worker in direct control of the flow of water should as a minimum, wear safety glasses and a face shield
complying with AS/NZS 1337.
Where liquids which can cause eye damage are being used at the workplace it may be necessary to use
a combination of a face shield visor and goggles or a full hood with shield.

PRESSURE CLEANER OPERATOR’S MANUAL
SAFETY
6
Leg and body protection
Workers should wear waterproof protective clothing complying with AS 3765.1-1990: Clothing for
protection against hazardous chemicals —Protection against general or specific chemicals or
AS 3765.2-1990: Clothing for protection against hazardous chemicals –Limited protection against
specific chemicals.
Leg and body armour manufactured from materials capable of withstanding the direct force of the water
jet should be used by water jetting operators where there is risk of injury. Liquid or chemical-resistant
suits should be worn where a risk assessment indicates these are required.
Hand protection
Hand protection complying with the recommendations of AS/NZS 2161.2:2005: Occupational protective
gloves - General requirements, AS/NZS 2161.3:2005: Occupational protective gloves - Protection
against mechanical risks or AS/NZS 2161.5:1998: Occupational protective gloves - Protection against
cold, should be worn where a risk assessment indicates this is required.
Foot and lower leg protection
Workers should wear protective footwear complying with AS/NZS 2210.3:2009: Occupational protective
footwear - Specification for safety footwear. A foot and lower leg guard or shield made from material
capable of withstanding the direct force of the water jet should be used where there is a risk of foot or leg
injury.
Further guidance on the selection of footwear is in AS/NZS 2210.1: 2010: Safety, protective and
occupational footwear - Guide to selection, care and use.
Hearing protection
Where noise cannot be eliminated or minimised so far as is reasonably practicable personal hearing
protectors as well as instruction and training in their use should be provided. Hearing protectors should
be selected in accordance with AS/NZS 1269.3:2005: Occupational noise management –hearing
protector program and tested in accordance with AS/NZS 1270:2002: Acoustics - hearing protectors.
Respiratory protection
Workers involved in high pressure water jetting operations should wear respiratory protection where
there is an assessed risk of injury that can be prevented by such equipment. Respiratory protection
should only be worn by workers who have been trained in its correct use.
A respiratory protection program should be implemented where there is evidence it could prevent injury
or disease. AS/NZS 1715:2009: Selection, use and maintenance of respiratory protective equipment
provides guidance on the implementation of respiratory protection programs.
Hazards and Symbols
This is the safety alert symbol. It is used to
draw attention to potential hazards.
Obey all safety messages that follow this
symbol to avoid possible injury or death.
The safety alert symbol is used in
conjunction with a signal word, a pictorial
symbol and/or safety message to assist in
identifying the hazard.
DANGER indicates a hazard which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazard which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazard which, if not avoided,
might result in moderate or minor injury.
NOTICE indicates a situation that could result
in equipment or property damage.

PRESSURE CLEANER OPERATOR’S MANUAL
SAFETY
7
Hazard Symbols
WARNING
Fuel and its vapours are extremely flammable and explosive.
Fire or explosion can cause severe burns or death.
When Adding or Draining Fuel
Shut-down engine and let it cool at least 2 minutes before removing fuel cap. Loosen cap slowly to relieve
pressure in tank.
Fill or drain fuel tank outdoors and in accordance with the LOCAL GOVERNMENT GUIDELINES.
DO NOT overfill tank. Always allow space for fuel expansion.
If fuel spills, wait until it evaporates before starting engine.
Keep fuel away from sparks, open flames, pilot lights, heat, and other ignition sources.
DO NOT light a cigarette or smoke.
When Operating Equipment
DO NOT tip engine or equipment at angle which causes fuel to spill.
DO NOT spray flammable liquids.
When Transporting or Repairing Equipment
Transport/repair with fuel tank EMPTY or with fuel shutoff valve OFF.
Disconnect spark plug wire.
When Storing Fuel or Equipment with Fuel in Tank
Store away from furnaces, stoves, water heaters, clothes dryers, or other appliances that have pilot light or
other ignition source because they can ignite fuel vapours.

PRESSURE CLEANER OPERATOR’S MANUAL
SAFETY
8
WARNING
Risk of electrocution.
Contact with power source can cause electric shock or burn.
NEVER spray towards a power source.
Ensure all nearby electrical equipment is appropriately protected again the ingress of water or debris.
WARNING
Running engines produce carbon monoxide, an odourless, colourless,
poisonous gas.
Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting,
confusion, seizures, nausea, fainting or death.
Some chemicals or detergents may be harmful if inhaled or ingested, causing
severe nausea, fainting, or poisoning.
ONLY operate High Pressure Water Cleaner outdoors.
DO NOT start or run engine indoors or in an enclosed area, even if windows and are open.
Keep exhaust gas from entering a confined area through windows, doors, ventilation intakes or other openings.
Use a respirator or mask whenever there is a chance that vapours may be inhaled.
Read all instructions with mask to be certain the mask will provide the necessary protection against harmful
vapours.
WARNING
Starter cord kickback (rapid retraction) can result in bodily injury.
Kickback will retract starter cord faster than it can be let go.
Broken bones, fractures, bruises, or sprains could result.
NEVER pull starter cord without first relieving pressure from all lines.
When starting engine, pull cord slowly until resistance is felt and then pull rapidly to avoid kickback.
After each starting attempt, where engine fails to run, point spray gun in safe direction and squeeze trigger to
release pressure.
Firmly grasp spray gun with both hands when using high pressure spray to avoid injury if spray gun kicks back.
WARNING
Contact with muffler area can result in serious burns.
Exhaust heat/gases can ignite combustibles, structure or damage fuel tank
causing a fire.
DO NOT touch hot components
AVOID hot exhaust gases.
Remove nearby combustible materials before operating pressure cleaner unit.
Allow equipment to cool before touching.
Keep at least 1.5m of clearance on all sides of pressure cleaner unit including overhead.