444-001-M - 0 HP Cleaner - Duo Boosters Basic

PRODUCT
INFORMATION
SURFACE CLEANING EQUIPMENT
HAVYARD LEIRVIK AS
VESSEL NAME/HULL NO.: 103
PROJECT NO.: OSE326-2
REVISION NO.: 00
DATE: 30.08.2011
• MATERIAL SPECIFICATION
1 • DATA SHEETS
• INSTRUCTION MANUAL – DUO BOOSTER

2 • SERVICE MANUAL - DUO BOOSTER
3 • TECHNICAL DESCRIPTIONS
4 • EC DECLARATION OF CONFORMITY
QUOTATION SPECIFICATION (2a) (INTERNAL)
Customer name: HAVYARD SHIP TECHNOLOGY AS

PO.no/ref.: 56958/103444002 / Siri Merete Olsen Expiry date: 2011-06-13
Yard:
Owner: HAVYARD SHIP TECHNOLOGY AS Currency: NOK
Hull No/Vessel: 103 / Vessel Type: SP
Project Id.: OSE326 Vessel Size: 0
Prepared by: DAASVATN, ANDREAS Flag/Class: NO / DNV
Number of Ships: 1
QUOTATION SPECIFICATION (2a) Page no: 1

Quote No. OSE326-2 Rev. Date: 2011-04-27
Product Group: 43 - SURFACE CLEANING EQUIPMENT Rev. No: 2
Item Qty Unit Prod.no Description Data Sheet No.
1.1 1 PCS 729384 DUO BOOSTER 3X690V 60HZ 160 BAR

DOUBLE PUMP AUTOM. 160BAR
1.2 13 PCS 623595 TAKE OFF VALVE N/A
6402023 ACID PROOF 316
1.3 4 LTH 586792 HEAVY DUTY HOSE 15 MTR 4305006
1402064 FOR 40C/A2K/03K
1.4 4 PCS 546036 COUPLING KIT ERGO 3000 4305004
MALE/FEMALE
1.5 2 PCS 633787 GASKET SET FOR HPC52 & HPC66
1119570 FOR C3 PUMP
1.6 2 PCS 665158 ERGO 3000 SPRAY GUN
WITH SWIVEL LOCK
1.7 2 PCS 659110 TORNADO LANCE 92CM WITH 06 NOZZLE
FOR HPC-66,62,53,52,42
1.8 1 PCS 546150 DOUBLE LANCE 2OOCM LONG
6400069 FOR 03K PUMP
1.9 3 PCS G43030 INSTRUCTION MANUAL
Instruction manual
Uno booster
Duo booster
Uno & Duo boosters

stationary high
pressure cleaners
Revision date: 02/2008

EN
Index
1 Safety Precautions and Warnings...............................................................................................4
2 Description 2.1 Application..............................................................................6

2.2 Operation elements ................................................................6
3 Installation 3.1 Temperature conditions ..........................................................7

3.2 Condition of distance..............................................................7
3.3 Wall mounting.........................................................................8
3.4 Water connection....................................................................8
3.5 Mains power connection.........................................................9
3.6 High pressure connection.......................................................9
3.7 Venting .................................................................................10
4 Operation 4.1 Connections .........................................................................12

4.1.1 High pressure hose - directly on the machine ...........12
4.1.2 High pressure hose - to outlet point...........................12
4.1.3 Spray handle - accessories .......................................13
4.1.4 Selection of spray lance.............................................13
4.1.5 Application of detergents (external injector) ..............14
4.1.6 Application of detergents (internal)............................15
4.2 Starting up............................................................................15
4.3 Operation - automatic start/stop ...........................................16
4.4 Double spray lance, pressure regulation ..............................16
4.5 Stop ...................................................................................17
4.6 Frost protection.....................................................................17
5 Fields of Application
and Working Methods 5.1 General Information...........................................................18
5.2 Typical cleaning tasks..................................................
.. 5.3 Detergents..........................................................
19
5.4 Working methods .................................................................20
6 Maintenance 6.1 Oil ...................................................................................21

6.2 Water filter ............................................................................21
6.3 Cleaning of high pressure nozzle .........................................22
6.4 Disposable waste .................................................................22
7 Trouble Shooting .....................................................................................................23
8 Technical Data .....................................................................................................25
9 Warranty .....................................................................................................25
EC Declaration of Conformity ...................................................................................................141
Revision date: 02/2008 Page 3

EN 1 Safety Precautions and Warnings
pressure washer if the electric distance of at least 15 cm to the

cable is all right (damaged surface to be cleaned.
electric cables can cause Never let children operate the
electric shock!) machine.
Do not use the machine if

Important instructions the electric cable or the high
pressure hose are damaged.
Connection to public mains
according to the applicable Do not cover the machine
regulations in your country. during operation or use it
IMPORTANT: Only use water in a room without adequate
without impurities! ventilation !
Before starting up your high
pressure washer for the first Before each use of your high If the overload protection device
time, this instruction manual pressure washer check the of the motor trips (motor stops),
must be read through carefully. most important visual parts. release the trigger of the spray
Save the instructions for later handle. Lock the spray handle
use. High pressure jets can be with locking device and turn the
dangerous if misused. Never start/stop switch to position „0“.
Only let instructed people direct the water jet towards Let the machine cool off for at
operate the machine. people, pets, electric wiring, or least 3 minutes!
the machine itself.
The machine must be placed in
General Spray handle and lance are a room where it is not exposed
affected by a thrust during to frost.
When using the high pressure operation - therefore always
washer all existing national hold the spray lance firmly with Never start the cleaner without
regulations must be observed. both hands. water supply. Even a short
Beyond the instruction manual water deficiency can damage
and the current national legal Never try to clean clothes or the sleeves of the pump.
regulations for prevention of footwear on yourself or other
accidents, also the approved persons.
rules for safe working must be Operation
observed. Operator and anyone in
immediate vicinity of the site Avoid damage to the electric
Any method of use endangering of cleaning should take action cables such as running over
the safety of persons or to protect himself from being by a car, squeezing, pull, knots
equipment is forbidden. struck by debris dislodged etc. and keep them away from
during operation. sharp or hot objects.
Before use Check that cleaning will not Avoid damage to the high
result in dangerous substances pressure hose such as running
Before starting up your high (e.g. asbestos, oil) being over by a car, squeezing, pull,
pressure washer check that it is washed off the object to be knots/kinks etc. and keep it
in a regular condition. Electric cleaned and harming the away from oil and sharp or hot
plugs and couplings must be environment. objects, as such may cause the
watertight. hose to burst.
Do not clean sensitive surfaces
Check the electric cables at made of rubber, fabrics or The cleaner can be used in
regular intervals for damage the like with the zero nozzle. zones classified as ZONE 2.
and wear. Only use the high With the flat jet nozzle keep a

EN
Important! Never use the when operating the machine. Note: If using another cable it
machine in an environment Only use the high pressure must be earthed and connected
where there could be a danger hoses, nozzles and couplings through the plug to the earth
of explosion (according to EN- prescribed by below! cable of your supply network
50014). in accordance with prescribed
For major repairs, please safety regulations.
Important! When the system contact your nearest WSS
has been in operation and service organisation. Always use a cable similar
thereafter stopped, there will to the one mounted on the
still be a working pressure in machine.
the pipeline and high pressure Mains power connection
hoses. Therefore you should Check cables before usage. Do
pay special attention to the not use damaged cables.
following:
Only let a qualified electrician
• Never dismount the high replace the electric cable.
pressure hose from the
machine during operation. Check the nominal voltage
Disconnect the machine, of the high pressure washer Safety Devices
close the shut-off cock and before connecting it to the
relieve the high pressure electricity supply. Safety Valve
hose of pressure prior to Check that the voltage stated The pressure side of the high
dismounting. on the model tag corresponds pressure pump is fitted with a
• Never dismount the high to your mains voltage. safety valve. This valve leads
pressure hose from the outlet the water back to the suction
point before it has been A circuit breaker must be side of the pump when the
securely closed and the high placed in the immediate vicinity spray handle is closed or if a
pressure hose has been of the machine. nozzle is blocked.
relieved of pressure.
• Prior to any service We recommend you to connect The safety valve is adjusted
interference in the machine the machine to a power source and sealed by the producer.
it should be disconnected with a Residual Current Device THIS ADJUSTMENT MUST
and the system relieved of (RCD) which will disconnect NOT BE CHANGED !
pressure by activating the the power supply if the leakage
trigger of the spray handle. current exceeds 30 mA for 20 Motor protection
milli seconds. The motor features an
Only connect to an approved overcurrent protection and
Repair and Maintenance socket with earth connection. built-in thermal switches for
protection of motor against
Only carry through the Only connect the machine to an overloading. In the event of
maintenance operations electrical installation made by increased power consumption
described in the operating an qualified electrician. (maloperation), the current for
instructions. Only use original the motor will automatically be
spare parts. The insulation of the electric cut out.
cable should be quite faultless
Do NOT make any technical and without any cracks.
modifications to the high
pressure washer. If you are in doubt about the
the mains power connection,
Warning! High pressure please contact a qualified
hoses, nozzles and couplings electrician.
are important for the safety

EN 2 Description
2.1 Application This high pressure washer has Only use the high pressure
been developed for professional washer for purposes described
use within: in this manual.
- agriculture The safety precautions must be

- light industry observed to prevent damage
- transport to the machine, the surface to
- building and construction be cleaned or severe personal
- service injuries.
Section 4 describes how to use

the high pressure washer.
2.1 Operation elements
UNO BOOSTER
4
1 Water connection with filter
6 2 Main switch
3 Starter switch
7 1 4 Stop switch
5 Check of oil level
UN
O BO
OST
ER
0
0 1 1
6 Pressure gauge
OST
ER
2 8
7 Connection of high pressure
O BO
UN
hose
8 Electric cable
5
3
DUO BOOSTER
4
7 1
DU
O BO
OST
ER
1 2
0 1+2
2 1+2
1
0
DU
O BO
OST
ER
2 8

3 Installation EN
3.1 Temperature conditions The machine should be

installed in a frost-free room.
This applies to pump as well as
pipelines incl. of outlet points.
Concerning outdoor outlet
Max 40 ˚C points it should be possible to
close and empty that part of the
Min 2 ˚C line which is exposed to frost.
The maximum ambient
temperature for the machine is
40°C.
3.2 Condition of distance In consideration of the cooling

system of the machine and the
accessibility of service, there
Min. 150 mm must be free wall space on
both sides of the machine. To
0
1
the right 150 mm at a minimum
and to the left 400 mm at a
Min 400 mm Min. 150 mm
minimum.
Min 400 mm
UNO BOOSTER:
The recommended installation
height for the machine is max.
1700 mm measured from the
upper edge of the machine.
Max. 1700 mm

EN
3.3 Wall mounting
190
645
UNO BOOSTER: Do not mount the machine

Only mount the machine on a on a wall where it will cause
solid wall construction suited for disturbances in neighbouring
the mounting of a machine. I.e. rooms (canteens, offices etc.).
a concrete or brick wall. If the
machine is not mounted verti- DUO BOOSTER:
cally, the oil level cannot be Place the machine on a plane
read correctly. When mounting floor.
the machine you should Machine feet have been
therefore compensate for a mounted under the machine.
lopsided wall to make sure that These must be adjusted so that
the wall bracket is placed in a the machine stands stable.
vertical position.
3.4 Water connection Max. water pressure: 10 bar

1 Max. water inlet temp.: 70°C
The machine features a water

tank, and no further protection
against return water into the
supply network is required. The
machine complies with EN 1717.
If there is a risk of running sands

or other impurities in the inlet
water, a sand filter (50 micron)
should be mounted beyond the
The water connection is internal filter of the machine
made through a flexible hose (for further connection data see
connected to the quick coupling section 8 Technical data).
on the water inlet (1) of the
machine. If mounting the by-pass hose,
the water inlet temperature can
The connection can be made be raised to 80°C. ONLY do
to a water supply network or an this if there is a separate water
internal water supply. A shut- supply (contact WSS)
off cock should be mounted distributor).
on the water supply network
in the immediate vicinity of the Clean the water inlet filter (1)
machine. once a month.

EN
3.5 Mains power Connect the machine to an

connection approved socket.
Check voltage, fuse, and cables

according to section 1 Safety
proceautions and warnings.
Connection data conc. power

consumption can be taken from
the model tag of the machine.
F
3.6 High pressure MPORTANT: When connecting
connection to a pipeline always use a
flexible hose connection from
the outlet of the machine (pos.
7) - order no. 711127. Contact
WSS for further
information.
The outlet of the machine can

be connected to a pipeline with
fixed outlet points, or standard
high pressure hoses can be
connected directly to the outlet
of the machine.
It is recommended to let a
service technician authorized
by ALTO prepare the pipeline.

EN
3.7 Venting UNO BOOSTER:
0 Turn start/stop switchto position

1 - 1 -. Open the outlet point.
Let the water run until all air has

escaped from the pump (even
water flow).
In the case of a recently

installed system, or if the
pipeline and the pump have
been emptied in any other way,
the system should be vented
by starting the pump and then
let the water run at each outlet
point of the pipeline at turns.
When connecting the high

pressure hose directly to the
machine, the system should
be vented by starting the pump
and activating the trigger of the
spray handle without having
attached the spray lance.
DUO BOOSTER:
In the case of a recently
2 installed system, or if the
1 1+2 pipeline and the pump have
been emptied in any other way,
the system should be vented as
0 follows:
1. At first start pump no. 1 and

let the water run from an
outlet point of the pipeline.
When connecting the high

machine, activate the trigger
of the spray handle without
having attached the spray
lance.
Let the water run until all air

has escaped from the pump
(even water flow).

EN
3.7 Venting (continued) 2. Stop pump no. 1. Then start

pump no. 2 and let the water
2 run from an outlet point of
1 1+2 the pipeline.
0 When connecting the high

machine, activate the trigger
of the spray handle without
having attached the spray
lance.
Let the water run until all air

has escaped from the pump
(even water flow).
3. Vent the pipeline by starting

one pump and then let the
water run at each outlet
point of the pipeline at turns
until all air has escaped from
the system.

EN 4 Operation
4.1 Connections The Unitor high pressure hose

4.1.1 High pressure hose with imprinted max. working
- directly on the pressure and temperature
machine 7 should be attached to the outlet
connection of the machine (7)
a by the quick coupling (a).
Max.extension hose: 50 m.
Danger of scalding!
Never dismount high pressure
hoses at water temperatures
above 50°C.
IMPORTANT: Prior to dismount-

ing of the high pressure hose
the machine should be stopped
and the shut-off cock closed.
Then activate the trigger of the
spray handle to relieve the high
pressure hose of pressure.
4.1.2 High pressure hose - In the case of a pipeline

to outlet point with fixed outlet points the
high pressure hose with
3 imprinted working pressure
1 and temperature should be
attached to the nipple of the
high pressure cock (1) by
the quick coupling (2). Upon
2 attachment turn the handle of
the high pressure cock (3) to
open position.
Danger of scalding!
Never dismount high pressure
hoses at water temperatures
above 50°C.
IMPORTANT: Prior to dismount-

ing of the high pressure hose
or when changing to another
outlet point the high pressure
cock should be carefully closed.
Then activate the trigger of the
spray handle to relieve the high
pressure hose of pressure.

EN
4.1.2 High pressure hose -

to outlet point Pipeline, max. length:
(continued)
UNO BOOSTER DUO BOOSTER
Ø12 x 1,5 - max. 50 m Ø15 x 1,5 - max. 25 m
Ø15 x 1,5 - max. 180 m Ø18 x 1,5 - max. 120 m
Ø18 x 1,5 - max. 500 m Ø22 x 2,0 - max. 250 m
When using max. pipe lengths,

only use a high pressure hose
of 10 m.
4.1.3 Spray handle - 1. Pull forward the quick

accessories coupling trigger (1) of the
1 spray handle.
2. Insert the nipple of the

spray lance (2) in the quick
coupling and release the
trigger.
2
3. Pull forward the spray lance
or any other accessory to
ensure correct mounting
before starting the machine.
NOTE!
Clean nipple of any impurities
each time the spray lance has
been dismounted.
4.1.4 Selection of You may use a double spray

spray lance MULTIPRESSURE lance as well as a single spray
P bar Q l/min. C N
lance with the machine. The
machine has been optimized
27 17 Hvid 1 to use spray lances with a type
27 35 Sort 2 06 nozzle. The max. pressure
50 17 Brun 1
53 33 Grøn 2
of the machine can be reduced
80 17 Blå 1 by using nozzles with a wider
80 27 Rød 2 diameter. See diagram.
107 17 Orange 1
107 26 Gul 2
152 17 Blank 1
P: Nozzle pressure
Q: Water volume
C: Colour code
N: No. of pumps (2 only DUO)

EN
4.1.5 Application of If you want to apply detergents Below you will find various
detergents (external) or disinfectants these should be types of outlet points with
dosed to the water through an
injector. In conjunction with the
injector it may be advantageous
to use a wall rack on which
spray lances, 2 pcs. of 25 l
containers as well as 10 m high
pressure hose can be placed.
Outlet point with detachable

injector
To be attached to the quick

coupling of the high pressure
cock.
To be used for dosing of
low-foaming detergents or
disinfectants.
Dosage 1-8%.
Outlet point with detachable

foam injector

cock.
To be used in conjunction with
foam lance for application of
high-foaming detergents or
disinfectants.
Dosage 1-5%.
Outlet point with cleaning

trolley and foam injector

cock.
To be used in the same way as
“Outlet point with detachable
foam injector”.
Makes it possible to place 4
spray lances, 2 pcs. of 25 l
containers as well as 20 m high
pressure hose.

EN
4.1.6 Application of This kind of detergent addition

detergents (internal) 2 is an option.
Insert the suction hose (1) from

A the machine in the container.
On the regulating knob (2) the
dosage can be set from 1-4%.
1 If the machine is mounted on
a pipeline, detergent will come
out of all outlet points. The pH
value MUST be between 5.5
and 8.5.
4.2 Starting up
6 2 Check that the oil level in the
3 oil reservoir (5) is between the
Min. and Max. markings.
0 1
Note: The oil level can only be
checked when the machine is
switched off.
The shut-off cock on the water
5 inlet should be open.
UNO BOOSTER:
1. Check oil level.
2. Turn the main switch (2) to
position - 1 -.
3. Push the green starter
0 button (3).
1 Check on the pressure gauge
(6) that a pressure is being built
up in the system. If a pressure
is not being built up, vent
the machine as described in
section 3.7 Venting.
DUO BOOSTER:
Position 1 =
Pump no. 1 in operation
Position 2 =
2 Pump no. 2 in operation
1 1+2
Positions 1+2 =
Pumps no. 1 and 2
0 in operation
1. Check oil level.

2. Turn the main switch (2) to
position 1, 2 or 1+2.
3. Push the green starter
button (3).

EN
4.2 Starting up (continued) Check on the pressure gauge

(6) that a pressure is being built
up in the system. If a pressure
is not being built up, vent
the machine as described in
section 3.7 Venting.
4.3 Operation - Always hold the spray lance

automatic start/stop with both hands!
The machine is automatically

activated when the trigger (1) of
the spray handle is activated.
When the trigger is released,

the machine automatically stops.
1 When the machine is not in

use, the trigger should be
locked with locking device (see
arrow).
4.4 Double spray lance,
pressure regulation The spray lance features 2
nozzles, a high pressure nozzle
and a low pressure nozzle.
1
High pressure mode
When the pressure reducing
valve (1) is completely closed
(turned clockwise - B), only the
high pressure nozzle is used
- high pressure mode.
Low pressure mode

When the reducing valve (1)
is completely opened (turned
counterclockwise - A), both
spray lances are used - low
pressure mode / possibility of
dosing detergents.
The pressure may be regulated

between these positions.

EN
4.5 Stop Danger of scalding!

Never detach high pressure
hoses at a water temperature
above 50°C.
Never detach the high pressue

hose while the machine is in
0 operation.
1
1. To stop the machine turn the
main switch (2) to position
- 0 -.
2. Close the shut-off cock of

the water inlet and activate
the spray lance or open the
high pressure cock to relieve
the pipeline / high pressure
hose of pressure.
4.6 Frost protection The machine should be

installed in a frost-free room.
This applies to pump as well as
pipelines incl. of outlet points.
Concerning outdoor outlet
Max 40 ˚C points it should be possible to
empty that part of the line which
Min 2 ˚C is exposed to frost.
IMPORTANT: For safety

reasons, hoses, spray lances
and other accessories should
always be thawed prior to use.

5 Applications and methods
5.1 General Information Efficient high pressure cleaning increase the efficiency of your
is achieved by following a few pressure washer. Here is some
guidelines, combined with your basic information about
own personal experience of cleaning.
specific cleaning tasks.
Accessories and detergents,
when correctly chosen, can
5.1.1 Soaking Incrusted or thick layers of dirt the product coat the dirty
can be loosened or softened up surfaces for around 30 minutes
by a period of soaking. This is before pressure washing. The
for example an ideal method result will be a much quicker
within cargo hold cleaning or high pressure cleaning process.
de greasing. The ideal
soaking method can be
achieved by using foam or
simple alcaline detergent. Let
5.1.2 Detergent and Foam Application Foam or detergent avoid “super clean” areas,
should be applied onto dry where the detergent collects in
surfaces so that the chemical higher concentration and
product is in direct contact with streams downwards. Let the
the dirt. Detergents are applied detergent react several minutes
from bottom to top, for example before cleaning off.
on a bulkhead, in order to
5.1.3 Temperature Detergents are more effective at be cleaning at temperatures of

higher temperatures. Greases, around 60°C. Oils, pollution and
oils and fats can be broken grease can be cleaning
down more easily at higher between 70° and 90° C (HPC66
temperatures also. Proteins can max. 85°C).
rotary or wash brushes offer

5.1.4 Mechanical Effect In order to break down tough this supplementary effect that
layers of dirt, additional cuts through dirt. Use a brush to
mechanical effect may be cut through e.g. traffic film.
required. Special lances and
sufficient for vehicle cleaning (in

5.1.5 High Water Flow or High pressure is not always the association with hot water).
High Pressure best solution and high pressure Higher flow levels give the
may damage surfaces. The possibility to rinse and flush
cleaning effect also depends away large amounts of dirt
upon water flow. Pressure levels easily.
of around 100 bar may be

5.2 Typical cleaning tasks
5.2.1 Cargo hold cleaning
Task Accessories Method
Cargo holds Chemical Foam 1. Soaking – apply foam to all surfaces (bottom to top)
Ballast tanks Injectors and wait for approx 30 minutes.
Foam lance 2. Remove the dirt from surfaces with the high pressure
Bulkheads Powerspeed lance lance or chosen accessory. Again, clean from bottom
and Long reach lance to top on vertical surfaces.
equipment 5,5m extendable lance 3. To flush away large quantities of dirt, change to low
pressure mode and use the higher flow to push away
Detergents the dirt.
Aquatuff 4. Use recommended chemical products and
Aquabreak PX methods to ensure good effect.
Machinery Tornado lance 1. Apply detergent to macinery or equipment surfaces in

Winches, Detergent injection order to soften up dirt and grime. Apply from bottom
Cranes Powerspeed lances to top.
Brushes 2. Proceed with cleaning using the high pressure lance.
Clean again from bottom to top. Use accessories to
clean in difficult to reach places.
3. Clean fragile areas such as motors, rubber seals
at lower pressure levels to avoid damage.
5.2.2 Deck and pool area cleaning on board cruise and passenger vessels
Deck and Standard lance 1. Apply detergent to deck or bulk head surfaces in
pool areas Detergent injection order to soften up dirt and grime. Apply from bottom
Powerspeed to top. In cases of particularly dirty areas, pre-
Brushes spray with a product such as Aquatuff in order to
remove traces of spills etc, then rinse at low
pressure and apply normal deck cleaning detergent.
Detergents Let detergents settle for 5 minutes before cleaning
Aquabreak PX off. Wooden surfaces can be cleaned using Teak Renewer.
Fore & Aft 2. Proceed with cleaning using the high pressure lance.
H.P. wash Clean again from bottom to top. Use accessories to
Uniwash clean in difficult to reach places. Use brushes in
Teak Renewer order to add a mechanical cleaning effect. Powerspeed
Metal Brite lances can be used for cleaning of tiles and glass
surfaces. Long reach lances or the extendable lance
can be useful for cleaning of the "rock climbing wall" if
here is one on board
3. Clean fragile areas such as furniture at lower
pressure levels to avoid damage.

5.2.3 Engine room and other heavy duty cleaning
Machinery Foam injectors 1. Apply thick foam over the surfaces to be cleaned.
surfaces Foam lance Apply on dry surfaces. Apply from top to bottom on
Tornado short lance vertical surfaces. Let the foam act for up to 30
Other Powerspeed lance minutes for the optimal effect.
equipment 2. After this time, clean down with the high pressure
Detergents lance or relevant accessory. Use high pressure to
Enviroclean dislodge large amounts of incrusted dirt or grime.
Cleanbreak Use lower pressure and high water volume in order
Seaclean to rapidly flush away loose dirt and rinse surfaces.
Seaclean +
Rusted or Wet Sandblasting 1. Connect the sandblasting lance to the pressure

damages equipment washer and place the suction tube in the sand.
surfaces prior 2. Always wear protective equipment during
to treatment sandblasting.
3. Spray the surfaces to be treated with the mix of
water and sand. Rust, paint etc will be stripped off.
4. Following sandblasting, protect surfaces against rust
(metal) or rot (wood).
These are merely several examples of cleaning tasks that can be solved by a pressure washer in
association with accessories and detergents. Each cleaning task is different, so please consult your
local dealer or WSS representative in order to discuss the best solution for your own cleaning problem.

6 Maintenance EN
It applies to the most exposed should be cleaned of dust and

components that a minimum sand.
of maintenance ensures a
prolonged and problem-free Prior to attaching the spray
operation. Therefore it will be lance or other accessories to
a good idea to make a habit of the spray handle, the machine
the following: should be started and the quick
coupling cleaned of dust and
Prior to attaching the water sand.
hose and the high pressure
hose, the quick couplings
6.1 Oil If the oil level in the oil level PROTECT THE
indicator (5) should drop below ENVIRONMENT
the minimum marking, send for Waste oil and oil sludge must
a WSS service technician as be removed as laid down in the
soon as possible. instructions.
6.2 Water filter To avoid debris entering the

high pressure pump, a water
1 filter (fine) is fitted at the water
inlet. Dependent on the purity of
the water, this filter will have to
be cleaned at regular intervals.
The filter can be removed when
the quick coupling (pos. 1) has
been unscrewed.
UNO BOOSTER DUO BOOSTER

The water tank also features a
filter (coarse) (2 pcs. in DUO
BOOSTER) ensuring that
flakes of scale are not entering
the pump. The filter should be
cleaned at regular intervals.
The two filters must not be
interchanged, as their filtration
capabilities differ.

EN
6.3 Cleaning of high A clogging up in the nozzle 1. Stop the cleaner and detach
pressure nozzle causes a pump pressure which the spray lance.
is too high, and a cleaning is 2. Clean the nozzle.
immediately IMPORTANT: ONLY use the
required. cleaning tool when the spray
lance is detached.
3. Flush the spray lance
backwards with water.
4. If the pressure is still too
high, repeat items 1-3.
6.4 Disposable waste This high pressure washer the removal of polluting and
consists of parts which can dangerous materials when
affect the invironment when replacing spare parts or
thrown away. Parts that can disposing of high pressure
pollute are as follows: washer.
Oil, painted/zinc-coated parts, It is recommended that you

plastics/plastic-coated parts. bring the rejected parts to
waste disposal areas or
Therefore, it is important to recycling plants that are
follow the laws concerning approved for the destruction of
these types of materials.

7 Trouble Shooting EN
You have chosen the best quality and therefore deserve the best service. To avoid unnecessary
disappointments, you should check the following before contacting the nearest WSS service
organisation:
Symptom Reason Action
Machine will not start > A fuse has blown • Change the fuse.
> Power/plug not connected • Connect power/plug.
> Thermal switches in motor • Let the motor cool. Start

activated the machine and check
that the working pressure is
> Thermal relay switched off not too high and that the
(red lamp is on) mains voltage corresponds
to the specifications.
DUO BOOSTER: > Water temperature too high • Lower the temperature of the
inlet water to max. 70°C. By-
pass 80°C.
Fuses blow > Installation does not • Change to an installation.

correspond to the ampere corresponding to the ampere
consumption of the machine consumption of the machine
at a minimum.
Change the fuse.
Working pressure too low > Nozzle worn • Replace the nozzle.
> Wrong spray lance • Replace the spray lance

(see section 4.4).
> Reduction valve of spray • Turn reduction valve com-

lance not adjusted to max. pletely counter-clockwise
pressure. (see section 4.4).
> Nozzle partly clogged up • Clean the nozzle

(see section 6.3).
Working pressure fluctuating > Water temperature too high • Lower the temperature of the
inlet water to max. 70°C. By-
pass 80°C.
> Insufficient water supply • Dismount the cabinet and

check that the water tank is
not drained of water during
operation of the machine. If it
is, clean the water inlet filter
of the machine. If that does

EN
Symptom Reason Action
Working pressure fluctuating not solve the problem, the

(continued) water supply for the machine
is insufficient.
NB! Avoid long, thin hoses
(min. 3/4").
> High pressure hoses too long • Dismount high pressure

extension hoses and retry.
Extension hose max. 50 m.
NB! Avoid long extension
hoses with many couplings.
> Air in the system • Vent the system

(see section 3.7).
> Water inlet filter clogged up • Clean filter (see sect. 6.2).
No working pressure > Nozzle clogged up • Clean nozzle (see sect. 6.3).
> No inlet water • Check that the shut off cock

of the water inlet is open.
Check that the water supply
meets the requirements
(see section 1.2).
> High pressure cock of outlet • Close all high pressure

point open. cocks not in use.
Machine starts and > Leaky hose/ • Repair leak.

stops pipeline/spray handle
Should other malfunctions occur than those mentioned above, please contact your nearest WSS
service organisation.

8 Technical Data EN
Model UNO BOOSTER DUO BOOSTER

Pump pressure 1) bar 160 160
Water volume, min./max. pressure l/min 19.1/17.3 19.1-38.3/17.3-34.6
Water tank, volume liter 3 7.5
Water connection:
Max. pressure, inlet water bar 10 10
Min. pressure, inlet water bar 1,0 1,5
Max. temperature, inlet water °C 70 (80, see section 3.4) 70 (80, see section 3.4)
Spray lance:
Nozzle type, h.p./l.p. 06/30 06/30
Thrust, max. N/kp 47/4,8 47/4,8
Pipeline, max. length m Ø12 x 1,5 - max. 50 Ø15 x 1,5 - max. 25
m Ø15 x 1,5 - max. 180 Ø18 x 1,5 - max. 120
m Ø18 x 1,5 - max. 500 Ø22 x 2,0 - max. 250
When using max. pipe lengths, only use a high pressure hose of 10 m.
1)
When using a 10 m (3/8") high pressure hose.
Sound pressure level LpA measured in accordance with ISO 11202 [DISTANCE 1m] [FULL LOAD]:
79 dB(A).
Data stated at 12°C hot inlet water.
We reserve the right to make alterations.
9 Warranty
Your ALTO product is • that only original Any illegitimate guarantee
guaranteed for 12 months from accessories have been repair will be invoiced. (I.e.
date of purchase (purchase applied. malfunctions due to causes
receipt must be presented) on • that the product has not mentioned in section “7.0
the following conditions: been exposed to abuse such Trouble shooting” of the
as knocks, bumps or frost. instruction manual).
• that defects are attributable • that the instructions in the
to flaws or defects in manual have been carefully
materials or workmanship. observed.
(Usual wear and tear as well
misuse are not covered A warranty repair comprises the
by the guarantee). replacement of defective part
• that repairs have not been but it does not cover freigh
carried out or attempted packaging charges. Besides we
by other than ALTO-trained refer to national Sale of Goods
service staff. Act.

EC Declaration of Conformity EG-Konformitätserklärung
The undersigned, representing the following manufacturer, Der Unterzeichnete, der den folgenden Hersteller vertritt:
ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund
declares that the product: erklärt hiermit, daß das produkt:
• • • High Pressure Washer • • • • • • Hochdruckreiniger • • •

type : UNO BOOSTER / DUO BOOSTER Typ : UNO BOOSTER / DUO BOOSTER
is in conformity with the provisions of the following EC directives, with konform ist mit den Bestimmungen der folgenden EG-Richtlinien, inklusive
subsequent amendments: deren Änderungen:
98/37/EEC, 73/23/EEC, 85/374/EEC, 89/366/EEC 98/37/EEC, 73/23/EEC, 85/374/EEC, 89/366/EEC
and furthermore declares that the following harmonised standards have been Desweiteren erklären wir, daß die folgenden harmonisierten Normen (oder
applied: Teile/Klauseln hieraus) zur Anwendung gelangten:
EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717 EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717
EN 55014, EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11 EN 55014, EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11
The following (parts/clauses of) national technical standards and und daß folgende nationale technische Normen und Spezifiktionen zur
specifications have been used: Anwendung gelangten:
IEC 60335-2-79 IEC 60335-2-79
Hadsund, 1 February 2002 Johan Ley Hadsund, den 1. Februar 2002 Johan Ley
Director of Technical Operations Director of Technical Operations
Verklaring van conformering aan EG-

Déclaration de Conformité EC
regelgeving
Le fabricant soussigné, Ondergetekende, functionerend als vertegenwoordiger van de fabrikant
déclare que le produit : verklaart dat het product:

• • • Nettoyeur haute pression • • • • • • Hogedrukreiniger • • •
type : UNO BOOSTER / DUO BOOSTER type: UNO BOOSTER / DUO BOOSTER
est conforme aux dispositions des directives CE suivantes, et voldoet aan de eisen gesteld in de volgende EG-regels, met daaropvolgende
aux amendements ultérieurs : wijzigingen:
98/37/EEC, 73/23/EEC, 85/374/EEC, 89/366/EEC 98/37/EEC, 73/23/EEC, 85/374/EEC, 89/366/EEC
et déclare également que les critères harmonisés ci-après ont été appliqués en verklaart bovendien dat de volgende geharmoniseerde standaarden zijn
: gehanteerd:
EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717 EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717
EN 55014, EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11 EN 55014, EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11.
Les critères techniques et spécifications nationales ci-après ont été utilisés De volgende (delen/artikelen van) nationale technische standaarden en
(parties/clauses) : specificaties zijn gebruikt:
IEC 60335-2-79 IEC 60335-2-79
Hadsund, le 1er février 2002 Hadsund, 1 februari 2002

Johan Ley Johan Ley
Directeur des OpérationsTechniques Directeur Technische Operaties
Declaración de conformidad de la CE Dichiarazione di conformità CE
El abajo firmante, en representación del fabricante Il sottoscritto, rappresentante del produttore,
declara que el producto: dichiara che il prodotto:
• • • Hidrolimpiadora de alta presión • • • • • • Idropulitrice ad alta pressione • • •

tipo: UNO BOOSTER / DUO BOOSTER tipo: UNO BOOSTER / DUO BOOSTER
es conforme con las disposiciones de las siguientes directivas de la CE con è conforme alle disposizioni delle seguenti direttive CEE e successive
sus consiguientes enmiendas: modifiche:
98/37/CEE, 73/23/CEE, 85/374/CEE, 89/366/CEE 98/37/EEC, 73/23/EEC, 85/374/EEC, 89/366/EEC
y además declara que se han aplicado las siguientes normas armonizadas: e dichiara altresì che sono stati applicati i seguenti standard generali:
EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717 EN 60335-2-79, EN 292, EN 294, EN 349, EN 457, EN 563, prEN 1717 EN
EN 55014, EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11 55014,
EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11
Se han utilizado las siguientes (partes/cláusulas de) normas y
especificaciones técnicas nacionales: Sono stati utilizzati i seguenti standard (parti/clausole) tecnici nazionali:
IEC 60335-2-79 IEC 60335-2-79
Hadsund, 1 de febrero de 2002 Hadsund, 1 febbraio 2002

Johan Ley Johan Ley
Director de Operaciones Técnicas Direttore dip. tecnico

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www.wilhelmsen.com/shipsservice
Service manual
Uno booster
Duo booster
Uno & Duo boosters

stationary high
pressure cleaners
INDEX
A Technical data 1- 2
B Construction 3- 7
C Function 8 - 13
D Trouble-shooting 14 - 19
Index
E Service/Repair 20 - 32
F Adjustment/Test 33 - 34
G Wiring diagrams 35 - 36
Technical Data A
Main technical data
UNO BOOSTER
DUO BOOSTER
Data apply to one pump only.

NOM. Tolerances NOM. Tolerance NOM. Tolerance
Voltage 3phase V 400 376 - 424 440 436-444 220 206-233
Frequency Hz 50 60 60
Power consumption, high pressure A 13 11,5 - 14,5 25 23,5-26,5 50 48,5-51,5
Power consumption, by-pass A
Power factor 0,85 0,88 0,88
Absorbed power kW 7,3 8,3 8,3
Shaft power kW 5,5 6,5 6,5
Number of revolutions m in -1 1440 1330-1550 1740 1700-1760 1740 1700-1760
W ater quantity, high pressure l/m in 17,6 17,2 - 18,0 18,6 18,2-19,0 18,6 18,2-19,0
W ater quantity, low pressure l/m in 19,1 18,6 - 19,6 20,3 20,0-20,5 20,3 20,0-20,5
Pump pressure at high pressure bar 158 153 - 163 182 177-187 182 177-187
Pressure, high pr., measured in outlet bar 152 174 174
Opening pressure bar

Opening pressure, measured in outlet bar 225 218 - 227 225 218-227 225 218-227
By-pass pressure bar 173 190 190

Cleaning effect kW 4,4 5,2 5,2
Motor guard setting A/pos. 15 27 52

By-pass time auto start/stop B/ex sec. 0/1 0/1 0/1
Electric cable length m 4 4 4
High pressure nozzle 1506 1506 1506
Low pressure nozzle 6535 6535 6535
Max. ambient temperature °C 40 40 40
Min. ambient temperature °C 2 2 2
Max. water temperature with tank °C 70 70 70
Max. water temperature direct water inlet °C 80 80 80
W ater inlet pressure Max bar 10 10 10
W ater inlet pressure Min bar 1,5/2,0 1,5/2,0 1,5/2,0
Suction height, primed m 0 0 0
Sound pressure Iso 3746 DB(A) 77 77 77

Density IP X5 X5 X5
1 bar = 14,223 Psi

Degree Celsius//Degree Fahrenheit: 2//30. 40//104. 70//158.
Liter/min//usga/min: 18,6//5. 20,3//5,3.
UNO/DUO-BOOSTER_GB02 1
Technical Data A
A1 DIODE PRINT ALTO
B1 PRESSURE SWITCH A1/8" NC at pressures < 25 bar

B2 REED SWITCH MK 8x30 15-20AW INTERTRONIC MAGNET switch
S1 Push button STOP 24V DC SCHNEIDER ZB5AW333/ZB5AWOB31

S2 Push botton START 24V DC SCHNEIDER ZB5AW343 / ZB4AWOB42
S10 Main Switch ( Pump selector DUO ) ALLEN BRADLY 194L-E-12-SerA, 5109530212
F1 THERMAL RELAY MOTOR PROTECTION PUMP 1 ALLEN BRADLY 193-EA4GB 12-32 A

F2 THERMAL RELAY MOTOR PROTECTIONE PUMP 2 ALLEN BRADLY 193-EA4GB 12-32 A
F3 Fuse for TRANSFORMER PRIMARY 2,5A TIME-LAG 5x20 mm
F4 Fuse for TRANSFORMER PRIMARY 2,5A TIME-LAG 5x20 mm
F5 Fuse on DIODE PRINT FOR TRANSFORMER SECONDARY 2A TIME-LAG 5x20 mm
F6 THERMAL SWITCH for high water temperature. DUO E21V 0705 75GR. + - 5GR
F7 HEAT SENSOR IN MOTOR 1 Max 170°C
F8 HEAT SENSOR IN MOTOR 2 Max 170°C
F9 PRESSURE SWITCH FOR WATER DEFICIENCY STOP SUCO 0,2 - 2 bar, switches on at pressures above 1 bar
T1 TRANSFORMER 230V - 19V / 24V ELEKTRODYN EBSI 78/36/50

50 / 60 Hz 400V - 19V / 24V ELEKTRODYN EBSI 78/36/50
460V - 19V / 24V ELEKTRODYN EBSI 78/36/50
K1 SAFETY RELAY FINDER TYPE 40.52 24V DC 2POL 8 amp

K2 FLOW AND LOW PRESSURE SWITCH RELAY SCHRACK V23092-A1024-A301 24V DC 6 amp:
K3 MOTOR CONTACTOR PUMP 1 400-460V ALLEN BRADLY 16A 24V AC 50/60 Hz
MOTOR CONTACTOR PUMP 1 230V ALLEN BRADLY 26,5 A 24V AC 50/60 Hz
K4 MOTOR CONTACTOR PUMP 2 400-460V ALLEN BRADLY 16A 24V AC 50/60 Hz
MOTOR CONTACTOR PUMP 2 230V ALLEN BRADLY 26,5 A 24V AC 50/60 Hz
H1 CONTROL LAMP FAULT 24V DC SCHNEIDER ZB5AW333/ZB5AWOB31

H2 CONTROL LAMP ON 24V DC SCHNEIDER ZB5AW343 / ZB4AWOB42
Sales spec
Sales spec
Structure B
Models
There are 4 diferent models:
UNO BOOSTER BASIC

DUO BOOSTER BASIC
UNO BOOSTER EXTENDED
DUO BOOSTER EXTENDED
UNO/DUO means one/two and refers to the number of pumps.
BOOSTER refers to the family relation to COMPACT BOOSTER and DELTABOOSTER.
BASIC refers to the electric control of the unit. It is built up of simple contact and relay functions only.
EXTENDED means an advanced control system (PLC) which is programmed to run with a number of different options.
The UNO BOOSTER is prepared for mounting on a wall
Foto of Uno
253,5
Start button S2 and Stop button S1 645
stand-by lamp and error lamp
High Main/Selector switch The DUO BOOSTER is fitted With 4 vibra-

pressure tion absorbing rubber supports which can
connector be adjusted.
Water inlet
connector
Pressure On the main/selector switch it is possible
gauge Power supply cable to select between
pump 1 only, pump 2 only, or pumps 1 and
By-pass 2 together.
adjustment
Motor ventilators
Oil level in
pump
2
1 1+2
Supports 0
Structure B
Frame/Pump
The UNO BOOSTER and the DUO BOOSTER have been built up with an all-welded frame and cover in a solid
construction of stainless steel. The motor pumps have been suspended on a rubber damper (6).
The cover for the electric box (14) is top-hinched and sealed with a soft sealing (15) glued on to the stainless steel
frame.
14 15
6
6
9
16
2
1
The pumps are 4-cylinder axial piston pumps with

solid ceramic pistons and valves of stainless steel.
The pump has been prepared for a continuous
working pressure of up to 210 bar.
The lubrication system includes an oli level indicator

hose visible from outside through the cover.
Structure B
Position of parts
Front view of the DUO BOOSTER:
Top-hinged plastic cover
Maon/selector switch (one
Stop button or two pumps running)
Quick coupling
Start button (female) for
water supply
Quick coupling
(male) for HP
connection Power supply
cable
Auto air-bleed
valve
Suction hose to UNO BOOSTER seen

pump
from the left side:
HP hose from Top-hinged plastic cover
pump Pressure gauge
Oil level
indication
Quick coupling
Motor connecting box (male) for HP
connection
By-pass
adjustment
Oil level hose
no Booster seen from above:
Uno Overflow connection
By-pass control valve block Tank cover Suction hose
Return flow hose to pump
Water inlet valve
Safety valve
Return hose fom air-bleed valve
DUO BOOST
BOOSTER ER seen from the top
without cove
coverr on the watertank:
Suction filters Float ball
The UNO BOOSTER is equipped with a water

tank (3 litres) made of plastic whereas the DUO
BOOSTER is equipped with a tank (8 litres) of
stainless steel. The support for the tank also
function as a tray leading the overflow water from
the tank to the floor. Both machines are equipped
with pressure gauge and the by-pass control
valve mounted to the left.
Structure B
Elecrical system BASIC
The UNO and DUO BOOSTERs have two different electric systems to control the functions.
"BASIC" is a simple relay controlled machine and "EXTENDED" is controlled by a PLC (Programable Logic Control) which
is programmed to be connected to a number of options.
Push buttons start/stop UNO BOOSTER BASIC (Photo)

S2/S1 Main/selector switch
The UNO BOOSTER or DUO BOOSTER BASIC has
no main control unit and can therfore only work as a
simple automatic start/stop machine controlled by a
flow and pressure switch.
Motor
Contactor
K3
Terminal Main power
Flow or low Motor
connector fuses F3,F4. Motor overload
pressure connector
block X1 switch
relayK2 block X1
Main control A1 Diode print Pressure switch Flow switch
relay K1 card 24VDC Control power B1 B2
Fuse F5 transformer
Motor contactor K3
Diode print card 24VDC
24VAC
Fuse F5 Flow or low press relay K2
Main control relay K1 Sub-relay for K3
Structure B
Elecrical system EXTENDED
S1 stop push S2 start push S10 Main swich

botton botton selector
DUO BOOSTER EXTENDED (Photo)
The UNO BOOSTER and the DUO

BOOSTER EXTENDED are also
equipped with a PLC offering the
possibilities of using a lot of optional
equipment such as remote control,
detergent valves, coin box, and pres-
sure-relief valve.
As a standard it is coded to shut down
after a period without any consumption.
On the PLC a diplay shows the running
time for each pump and indicates errors,
such as motor overheated, water too
hot, and motor overloaded.
Fuse F3, f4 F1, F2,
Terminal X1 A2 PLC Motor overload
T1 Control
1-6 A1 Diode print transformer switch
Terminal X1 fuse F5 K1, K2,
24 VAC Terminal X1
+ / -. 13-14. Motor contactor
20, 21, 24.
A1 Diode print. A2 PLC F6 Temp. switch water

Fuse F5 (by-pass valve block)
Motor pumps1 and 2 S10 Main switch, pump selector
Function C
UNO BOOSTER BASIC disconnected
The flow system is illustrated in pressure-relieved, disconnected condition. The water tank, however, is full.
+
. .1 0 0 . . . . . . .1
5 0 . . . . . . .2 0
.... . . .5 0 . . ...
;
0 0
* 8
8
*
N C
2
P1: The high-pressure pump is conneced to the water tank on the suction side and to the valve block on the high-
pressure side.
V1: The overflow valve opens at a pressure > the working pressure. Its function is to lead water back to the tank
when the perssure exceeds the Working pressure (normaly 160 bar)
V2: The non-return valve protects against backflow, also from other machines on the pipeline. It maintains the
pressure in the line even when the pressure drops in the pump.
B1: The pressure switch starts the pump if the pressure drops below 25 bar.
B2: The flow switch gives a signal to start the pump if the consumption in the pipe line is > 3 l/min.
C1: The pressure accumulator obtains the pressure peaks and gives the starting flow to the flow switch.
Y1: The float valve keeps the water level in the tank constant.
Function C
UNO BOOSTER BASIC stand-by
+
. .1 0 0 . . . . . . .1
5 0 . . . . . . .2 0
.... . . .5 0 . . ...
;
0 0
* 8
8
*
N C
2
The main switch S10 has been turned on and the start button S2 activated. Motor P1 is now controlled by the flow and
peessure switches B1and B2. The pump will build up a pressure in the system. As soon as the pressure is > 25 bar
and the outgoing flow has stopped, the motor contactor K3 will open and the motor P1 stop. The motor vil do a few turns
before it stops, and the valve V1 will just open and close again. The pressure will raise up to 160 -170 bar. If the pipeline
is tight, the pressure will remain even if the pressure in the pump disappears.
Red: 400V AC. Green: 24V AC. Blue: 24V DC Plus. Purple: 24V DC Minus. Yellow: Not activated
Function C
+ UNO BOOSTER BASIC operation
. .1 0 0 . . . . . . .1
5 0 . . . . . . .2 0
.... . . .5 0 . . ...
;
0 0
* 8
8
*
N C
2
When one user activates the spray handle, C1 will expand and give a water flow through B2, and the switch closes. The
relay K2 will activate contactor K3 and the motor will start. Because it is the flow that gives the signal to start, the pressure
will only drop a little.
When the user stops, the flow stops and in the same moment the motor stops and so on.
Red: 400V AC. Green: 24V AC. Blue: 24V DC Plus. Purple: 24V DC Minus. Yellow: Not activated
Function C
DUO BOOSTER BASIC operation
The DUO BOOSTER BASIC almost works the same way as the UUNO BOOSTER BASIC exept for the situation
where two pumps are running but only one user is working with an 06 nozzle (one pump in by-pass mode).
0 ..
+
...
. .5
;
* 8
8
*
N C
2
Two pumps are running but only one is needed. Therefore the pressure rises, and the overflow valve V1 opens and
lets the water by-pass to the tank.
As soon as the consumption stops, the flow will stop and both pumps will stop at the same time.
Function C
DUO BOOSTER EXTENDED
The EXTENDED models are almost working like the BASIC models, but the PLC offers some options like time delay and
automatic functions.
PUMP B1 B2 F6 F1,F2 STATUS DELAY FUNCTION

STEP OPERATION PRES. FLOW WAT. OVH. OVERLOAD SEC
OUT-1 IN-3 IN-4 IN-7 IN-11
PRES MACHINE
0 0 0 0 1 0 START 0 ON
START
1 1 1 1 0 0 0 PUMPS
STOP
2 1 0 0 1 0 0 1 PUMPS
PUMPS
3 1 0 1 1 0 0 0 RUN
PRES PUMPS
4 1 0 1 1 0 STOP 0 STOP
WATER PUMPS
5 1 1 0 1 0 SHORTAGE 5 STOP
WATER PUMPS
6 1 0 1 0 0 OVH. 0 STOP
WATER PUMPS
7 1 1 0 0 0 OVH. 0 STOP
MACHINE MACHINE
8 0 1 0 1 0 SHUT-DOWN 2150* OFF
MACHINE MACHINE
9 1 1 0 1 1 SHUT-DOWN 5 OFF
MACHINE MACHINE
10 1 0 1 1 1 SHUT-DOWN 5 OFF
* Shut down time, can be cancled if needed, see Ajustment/test.
Function C
Valve block
Pressure
compensator
Connection from
Reed switch Clamp pump P1
Temperature switch
(DUO only)
Quick coupling for

Connection from
external connection
pump P2
Ajustment screw,
Connection to
by-pass
water tank
Pressure switch (NC)
N C
Flow valve with 2 magnets

Non-return valve
Back flow valve
Trouble-Shooting D
Functional Requierments
To ensure a problem-free operation, the following requirements must be fulfilled:
1. Machine and pipeline must be free of air and tight.
2. The water temperature must not exceed 70°C.
3. The water must be without any impurities as for instance floating sands > (50 µ).
4. The water supply must always be sufficient.
5. The ambient temperature must not exceed 40°C.
6. Variations in the mains voltage must be max. ±10% of the rated value.
If the above-mentioned requirements are met, it must be possible, at any time, to tap off 17 l/min. x
the number of pumps under a steady pressure of 160 bar on a pipeline connected to a BOOSTER
and equipped with original standard nozzles.
If these requirements are met and you still experience operational break-downs, there are faults on
the system.
Trouble-Shooting D
Check list
When trouble-shooting it is will be a great help if you can locate the fault as being either an exter-
nal fault or an internal fault.
External faults are due to either improper maintenance, incorrect operation or operation under
particularly straining conditions.
External faults usually represent the following:
The below-mentioned conditions have been checked and found o.k.:
Yes No Comments
1. Installation fuse blown ....................................
2. Plug defective .................................................
3. Cable bursting .................................................
4. Too long or defective extension cables ..........
5. High/low pressure nozzle blocked or worn....
6. Spray handle defective or leaky ......................
7. High pressure hose too long or defective ......
8. Water inlet filter blocked (dirty water) .............
9. Inadequate supply of mains water ..................
10. Air or dirt in pipe system .................................
11. Detergent system blocked (dried-up) .............
12. Inlet water too hot ...........................................
The internal faults require a systematic going through of the motor pump by an WSS technician.
In order to establish the reason of the fault with certainty, it may be a help to use the over-leaf yes/
no diagrams.
Trouble-Shooting D
Starting-up problems
The first time a UNO/DUO BOOSTER is started up, either because it is a

new plant or because it has undergone some changes or a repair, the
following typical faults may occour:
The pump shakes and makes a noise.

Stop the machine immediately.
Symptom: The pressure is too low and fluactuating.
Air in the pump. Loosen the venting screw of the pump.

Reason 1:
Start the machine and run without nozzle.
Dirt in the suction valves or pressure Clean the valves and check that the filter
Reason 2: valves. in the tank is clean.
Too long reaction time before a pump starts

Symptom: Check.
up.
Reason 1: Air in the pipeline. Vent the whole pipeline.
Reason 2: Flow switch B2 not working. Ajust or change the Reed switch.
Symptom: Pressure to low. Check.
Reason 1: Safety valve open / leaking. Check safety valves.
Reason 2: Overflow valve leaking. Check/adjust the valve.
Trouble-Shooting D
Machine does not start
Open the test valve. UNO/DUO BASIC
Turn the main switch. Select
one pump to start.
Push the green button.
Is the
No Yes
red light on?
Open the el. box and shortly Check

press the motor contactor overload relay
down manually FI
No Does Yes
the motor turn?
Check
Check power
fuses F3, F4,
supply
F5
OK OK
On print card
Check
between 8 and 3
Replace 24V DC
motor
Make a connection
between 8 on print card and
X1-2
No Does Yes
the motor turn ?
Replace
Check Check
K1.Or OK
F7 start/stop
pressure
switch
switch B2
Trouble-Shooting D
Machine does not start
UNO/DUO EXTENDED
Red light is flashing
Motor overload switches
Check the motor overload swiches F1 and F2.

If the indicator is yellow, it has tripped and must be
Set on auto
reset. Normally it is set on auto from factory.
Indicator (yellow)
¤ Turn main/selector switch S10 to -0-.(POWER OFF)

* Let the Pressure escape from the system.
* Use an ohmmeter with sound.
¤ Place one leg in + and the others in terminals 1 to 12. Check according to diagram.
+ IN terminal Conne ction When

Test
+ 1: S1 stop X
+ 2: S2 start O
+ 3: B1 press X
+ 4: B2 Flow O
+ 5: K1 motor O
+ 6: K2 motor O
+ 7: F6 water (X) DUO
+ 8: xx inlet H --------- OPTION
+ 9: xx detergent A O OPTION
+ 10:xx detergent B O OPTION
+ 11: F1 F2 overload O
+ 12: xx coin box --------- OPTION
When red light is flashing, the display will show:
1: Water overheated. The signal comes from F6 and means that the water is more that 75°C.
2: Water shortage or motor overheated. The signal comes from F1, F2 or the thermic in the windings
or B2 flow.
This will appear when motor is running without flow and pressure (<25 bar) for more than 5 sec.,
or if the temperature of the windings in the motor is >160°C or ampere consumption >14 amps.
Trouble-Shooting D
Pump pressure low
The reason why the pump pressure is too low may have been one of the following:
1. The number of nozzles in use exceeds the pump capacity, or the nozzles used may be worn.
2. Pipeline narrowed due to scale or dirt.
3. Pre-nozzle of multipressure spray lance clogged up.
4. Pipeline leaky.
5. A pump does not run.
6. Safety valve of pump adjusted too low or defective.
7. Overflow valve V1 adjusted too low, worn or clogged up.
8. Suction and/or pressure valves worn or clogged up.
9. Pressure sleeves worn.
10. Air in the pump.
For the encirclement of the reason of the fault, the following diagram can be used.
The plant is a 160 bar plant. In the case of a 120 bar plant, proportionally lower values apply.
Service / Repair E
Repair Times
Page Contents Service time / pump
E3 Safety valve ½ hour
E4-5 Valve cylinder head 1hour
E6-7 Cylinder block ½ hours
E8-9 Wobble disc / motor 1½ hours
E11 Overflow valve V1 ½ hour
F1 Starting-up of plant 1 hour
F2 Basic adjustment ½ hour
F4 Electric test ½ hour
UNO/DUO BOOSTER_GB01 20
Service / Repair E
Survey
Motor Wobble disc Cylinder block Cylinder head Safety valve
Page Contents Service time / pumps
3 Safety valve 15 min.
4-5 Cylinder head 1 hour
6-7 Cylinder block ½ hour
8-9 Wobble disc / motor 1½ hours
Service / Repair E
Safety Valve
Pressure side
Safety valve
Suction side
At the factory the safety valve has been set at opening pressure = working pressure + 50 bar.
When checking-up the machine, the adjustment should be checked and maybe adjusted.
When mounting, use grease to make the ball and the thrust plate stick to the spring.
The seat is screwed on using a 10 mm box spanner (no gasket required).
Before testing with a pressure gauge, you should make sure that 2 threads are visible behind
the lock nut.
NOTE: Before starting up the pump, make sure that the valve of the test pressure gauge is
open. Ajust the flow switch B2 10 mm to the right. Select the pump and push the start button.
Slowly close the valve. Never exceed 250 bar.
10 mm special key no: 1206754
Adaptor
no:1220126
Test pressure gauge

no:1206358
6 mm hexagon Test tube no: 1211994

box wrench
Service / Repair E
Cylinder Head 1
Furrow for lubricating water

Pressure valve seat
ey
nn
K e
17
18
Seat of suction valve
Nylon ring
96
Textile sleeve (hard) 99
19 97
99
Back-up ring 97
Rubber sleeve (soft) Suction valve 18 and pressure valve 19 are one kit and
shall allwais be changed compleet.
12
Dismounting and mounting by hand. Attach Dismount suction valve seat with a mandrel.
big O-ring using grease. Note position of the Now press out the pressure valve with a 2 mm
casting "smile". punch. Check the surface of the seats.
Tighten the eight 10 mm bolts with 27 Nm. Mounting only by hand.
Mandrel no:1216506
Service / Repair E
Cylinder Head 2
Lock/back-up ring
O-ring
Rubber sleeve secondary tightning
Thrust collar
Back-up ring
Textile sleeve
Expansion/back-up ring
K
en
ne
y
Suction valve Pressure valve
O-ring
Mounting of textile sleeves by means of tool no. 1220090. It is an advantage if the sleeves have
been in a water bath for 3-4 hours before mounting them. Do not forget to blow through the
ducts.
Service / Repair E
Cylinder Block 1
Washer
O-ring
Torque moment: 37 NM
Oil sleeve
Back-up ring
Drain off the oil. Loosen the 8 bolts gradually (because of the spring load). Special box head no.
1206762 may be used.
Mount new O-rings on studs with tool no. 1206812.
Always replace secondary sleeves when

replacing pressure sleeves.
Check that there is a free passage from
the drain holes.
97
99
16
Kit 16 consists of two new parts and must always be replaced at the same time.
Service / Repair E
Cylinder Block 2
Carefully tip out the oil

sleeves with an
adequate screwdriver
and discard them.
Be careful not to
scratch the surface.
Before mounting the

new sleeves, it will be
a good idea to moisten
the sleeves with soapy
water.
Mount new oil sleeves

with punch no.
1220429.
Carefully knock or
press them home.
Check the piston for

Oil sleeve L. P H.P.
wear in the pressure
area and the area for
oil sleeves.
Check the ceramic for

cracks. Remove any
Pressure area Stainless steel Ceramic coating.
Service / Repair E
Motor / Wobble Disc 1
The motor consists of a stator with windings and a rotor with shaft which are kept in the right
place with a bearing in the N bearing cover and the inner needle bearing of the wobble disc in the
D bearing cover.
The fan blade 4 has been pressed on to the rotor with a locking ring 5 and mounted with 2
pointed screws.
N stator rotor D The thrust plate of the

4 wobble disc 23 has been
23 fixed with the tape 22.
Washer 21 ensures that
the needle bearing 24 is
22 kept free of the oil
x
sleeve x.
21
27
W
5
24
"
'
#

%
&
#
$
' %
Y
Dismount locking ring (27). The
wobble disc is easily dismounted
# with puller no. 1205715 and special
& legs no. 1206150/1206168.
x
! Do not forget to remove key (17)

before dismounting the D-bearing
cover.
" Check bearing surfaces of wear. If in
! '
# doubt, replace kit (28) complete after
! $
!
% approx. 1,400 hours.
&
Service / Repair E
Motor / Wobble Disc
When mounting the D-bearing cover complete,

protect the U sleeve with tool no. 1206598 which is
placed on the shaft, before placing the cover.
1206598
"
#
50 Hz wobble disc no. 10
60 Hz wobble disc no. 4
$ %
!
!
!
When mounting the wobble disc, lubricate the bearings with

oil. The big roller bearings (25) and (31) are identical. Do not
forget to mount the circlip (27) on the shaft. Refill with ½ l oil
type Castrol Alphasynt ISO 150 or BP Bartran HV ISO 100.
Part no. 26 Part no. 32
Check the bearing surfaces for wear. As long as the wear is even and shiny without pittings or
grooves, the wobble disc can be re-used.
N.B.: The illustrated wobble disc has been working for 1,000 hours with a pressure of 180 bar.
Service / Repair E
Motor / Technical Data
The motor is protected against overload by a motor protection device (overload cut-out) which is
adjusted to the nominal power consumption at working pressure + 1 amp.
Class: F
IP 45 (front cabinet closed)
Thermal switch (bimetalic type) mounted in the windings between 2 phases. Opens at 160
±10°C. Leads out of motor are marked 9 and 14, and leads from the motor plug marked 7 an 8.
Power absorption of motor: 6.7 kW

Output of motor: 5.5 kW
Rev. of motor at 1/1 load, 50 Hz: 1,440 rev./min.
Rev. of motor at 1/1 load, 60 Hz: 1,730 rev./min.
COSϕ of motor: 0.83
Efficiency of motor: 0.79
Star connection
Delta connection
) ~3 M o t. 1 1 2 M
E R 4 /4 -7 6 P -1 4 5 3 9 0 9 6 4 5 - 1 3
E IN B A U
3 8 0 /2 2 0 c o s
j I P 0 , 85 5
4
1 2 /2 1 A 1 4 3 5 1 /m in 5 0 H z
5 ,5 K w S 1
Y / 3 8 0 -4 8 0 /2 1 0 -2 6 0 V c o s j 0 ,8 6 -0 ,7 7
1 1 - 1 0 ,5 /2 0 -1 8 ,5 A 1 7 3 0 1 /m in 6 0 H z
5 ,5 k w S 1 T h . C l. F
W S K 1 6 0 ° C
T 1 1 2 2 4 2 7 5 H 1 7 k g E N 6 0 0 3 4
The motors are fitted with model tags of the 2 variants above.
Service / Repair E
By-pass valve block
Pressure accumulator
The valve blook is mounted on the

back side on to rubber supports. and
accessible from the top when the
cover is removed. This picture shows
an Uno Booster.
By-pass connection hose

High pressure hose
from pump
10
8
9 7
6
Presure switch
The pin is a part

of the kit 10 .
It is mounted with
Locktite.
Dismount with a The profile
The flow switch B2
screwdriver after ring must be
can be dismounted
heat treatment. correctly
from the left side
mounted
Notis the shock
valve inside the
quick coupling
Remove the Plug Press out the cone with

a punch from behind,
Pull out the guide (on a DUO it is
by means of a 3mm possible through the
screw Pull out cone water tank)
Left side frame.
with all springs
by means of a
3mm screw
Service / Repair E
Pressure relieved spray handle
The pressure relieved valve differs from the normal type in the way that the valve plunger sticks
out of the valve housing in both ends. Because of the difference in diameters the pressure relief
is achieved. The cost of this construction is that there are more gaskets where a leak may
occur.
%
&
' !
Nylon valve seat Lock washer
O-ring U -sleeve
Slide ring
Spring thrust washer
For mounting of O-ring / slide ring and U sleeve, tool no. 1206747 can be used with success.
The function of the lock washer is to keep the U sleeve in position.
Service / Repair E
ERGO 3000
Adjustment / Test F
New installation
From the factory

the BOOSTER has been adjusted to the pressure stated on the model tag - typically 160 bar.
Before leaving the factory, the machine was subjected to a test run. All optained data have been noted and
can be called back if needed.
Before starting up
the BOOSTER, it will be a good idea to rinse the water inlet filters and thoroughly clean them.
Check the capacity of the water supply network by watching the water level in the tank when the machine is
running with max output. Run this test with a pressure of 50 bar max.
If the ball is moving up and down in short strokes, the water supply is o.k.
You can also check with a pressure gauge that the pressure is min. 2 bar at max. consumption.
Venting of pumps:
Open more take off points. Start the machine. All pumps will then start up. The pressure is kept between 25
40 bar. Loosen the venting screws of the pumps one by one.
Venting / washing through of pipeline:

Connect the water supply, preferably hot water directly to the pipe installation and wash the system
systematically through to the remotest take off point. When all air has escaped from the system, the pressure
hose of the BOOSTER is connected to the pipeline and the machine can be started.
Another method of venting is to use the BOOSTER to wash air out of the pipes. If using this method it is
important that the pressure is kept as low as possible, max. 25 - 40 bar, meaning that at least one take off
point is open during the washing through.
Test air in system / density:

Close all take off points. Start the machine. On extensive pipelines, 100 m and more, pumps will start to build
up the pressure to max. in a few seconds (max. 5 sec.). If 5 sec. are exceeded, a new venting should be carried
through. Let the machine stop automatically. Check that the pressure remains unchanged for at least 10 min.
Pressure drop in pipe test:

If you have any doubts about the pipe installation concerning the dimensioning, it will be a good idea to test
the pressure drop in the pipeline before delivering the plant.
Place the test pressure gauge 1206358 with adaptor 1220126 on the doubtful take off point (remotest). Attach
hose and spray lance to be used, open the valves completely and start the consumption. The pressure drop
must not exceed 15 bar.
Extended only
Interruption of Shut-down time*
Specially on installations without remote control, it can be necessary to cancel the auto shut down time.
This can easily be done by pressing down and hold the - button, now press the + button 10 times
Then press 10 times.

First press and hold
Press once to cancel.
Adjustment / Test F
Standard adjustment
If you are in doubt about the conditions of the machine, it will be a good idea to go through all
adjustments systematically.
1: Check that the water supply is o.k.

2: Check that all terminals and plugs have been correctly mounted.
3: Check settings of motor protection, see page A1.
4: Check that all 3 phases are alive and that there is 24V on the secondary side of the transformer.
* Close the main valve on the HP side to cut off the machine from the pipeline.
* Roughly adjust the overflow valve V1. Adjust the screw, pos. 6 (see page E11) as far as it will
go and then 2 ¾ turns backwards.
Starting up
* Only let one pump start.

* Let the pump run until it stops automatically with pressure.
Set point Start point
B2 By.pass valve Block
Stop point
5: Move the Reed switch B2 to the right until the pump starts.
6: Fine adjust the overflow valve V1 to working pressure + 10 bar. (170 bar).
7: Move the Reed switch B2 to the left until the pump stops +5 mm and fix it.
8: Test the safety valves of all the pumps, see page E3.
9: Check non-return valve V2 Start up the pump and let it run until it stops. The system is now
pressurized. Loosen the venting screw of one of the pumps.
If the pressure on the pressure gauge remains unchanged, the non-return valve is in order.
The machine is now ready for operation.
Wiring Diagram G
UNO BOOSTER BASIC 3~, Y
with/without Options
Wiring Diagram G
UNO BOOSTER EXTENDED 3~, Y
Wiring Diagram G
UNO BOOSTER BASIC 3~, ∆
Wiring Diagram G
UNO BOOSTER EXTENDED 3~, ∆
Wiring Diagram G
UNO BOOSTER EXTENDED 1~
Wiring Diagram G
DUO BOOSTER BASIC 3~, Y
Wiring Diagram G
DUO BOOSTER BASIC 3~, Y
Wiring Diagram G
DUO BOOSTER EXTENDED 3~, Y
Wiring Diagram G
DUO BOOSTER EXTENDED 3~, ∆
Wiring Diagram G
DUO BOOSTER EXTENDED 1~

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PRODUCT

SURFACE CLEANING EQUIPMENT

VESSEL NAME/HULL NO.: 103

PROJECT NO.: OSE326-2

• INSTRUCTION MANUAL – DUO BOOSTER

Customer name: HAVYARD SHIP TECHNOLOGY AS

QUOTATION SPECIFICATION (2a) Page no: 1

Item Qty Unit Prod.no Description Data Sheet No.

1.1 1 PCS 729384 DUO BOOSTER 3X690V 60HZ 160 BAR

Uno & Duo boosters

Revision date: 02/2008

1 Safety Precautions and Warnings...............................................................................................4

2 Description 2.1 Application..............................................................................6

3 Installation 3.1 Temperature conditions ..........................................................7

4 Operation 4.1 Connections .........................................................................12

5.4 Working methods .................................................................20

6 Maintenance 6.1 Oil ...................................................................................21

7 Trouble Shooting .....................................................................................................23

8 Technical Data .....................................................................................................25

EC Declaration of Conformity ...................................................................................................141

Revision date: 02/2008 Page 3

pressure washer if the electric distance of at least 15 cm to the

Do not use the machine if

Revision date: 02/2008 Page 4

Revision date: 02/2008 Page 5

- agriculture The safety precautions must be

Section 4 describes how to use

2.1 Operation elements

Revision date: 02/2008 Page 6

3.1 Temperature conditions The machine should be

3.2 Condition of distance In consideration of the cooling

Revision date: 02/2008 Page 7

3.3 Wall mounting

UNO BOOSTER: Do not mount the machine

3.4 Water connection Max. water pressure: 10 bar

The machine features a water

If there is a risk of running sands

Revision date: 02/2008 Page 8

3.5 Mains power Connect the machine to an

Check voltage, fuse, and cables

Connection data conc. power

The outlet of the machine can

Revision date: 02/2008 Page 9

3.7 Venting UNO BOOSTER:

0 Turn start/stop switchto position

Let the water run until all air has

In the case of a recently

When connecting the high

1. At first start pump no. 1 and

When connecting the high

Let the water run until all air

Revision date: 02/2008 Page 10

3.7 Venting (continued) 2. Stop pump no. 1. Then start

0 When connecting the high

Let the water run until all air

3. Vent the pipeline by starting

Revision date: 02/2008 Page 11

4.1 Connections The Unitor high pressure hose

IMPORTANT: Prior to dismount-