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
Before starting up your high
pressure washer for the first
time, this instruction manual
must be read through carefully.
Save the instructions for later
use.
Only let instructed people
operate the machine.
General
When using the high pressure
washer all existing national
regulations must be observed.
Beyond the instruction manual
and the current national legal
regulations for prevention of
accidents, also the approved
rules for safe working must be
observed.
Any method of use endangering
the safety of persons or
equipment is forbidden.
Before use
Before starting up your high
pressure washer check that it is
in a regular condition. Electric
plugs and couplings must be
watertight.
Check the electric cables at
regular intervals for damage
and wear. Only use the high
pressure washer if the electric
cable is all right (damaged
electric cables can cause
electric shock!)
Important instructions
Connection to public mains
according to the applicable
regulations in your country.
IMPORTANT: Only use water
without impurities!
Before each use of your high
pressure washer check the
most important visual parts.
High pressure jets can be
dangerous if misused. Never
direct the water jet towards
people, pets, electric wiring, or
the machine itself.
Spray handle and lance are
affected by a thrust during
operation - therefore always
hold the spray lance firmly with
both hands.
Never try to clean clothes or
footwear on yourself or other
persons.
Operator and anyone in
immediate vicinity of the site
of cleaning should take action
to protect himself from being
struck by debris dislodged
during operation.
Check that cleaning will not
result in dangerous substances
(e.g. asbestos, oil) being
washed off the object to be
cleaned and harming the
environment.
Do not clean sensitive surfaces
made of rubber, fabrics or
the like with the zero nozzle.
With the flat jet nozzle keep a
Revision date: 02/2008
distance of at least 15 cm to the
surface to be cleaned.
Never let children operate the
machine.
Do not use the machine if
the electric cable or the high
pressure hose are damaged.
Do not cover the machine
during operation or use it
in a room without adequate
ventilation !
If the overload protection device
of the motor trips (motor stops),
release the trigger of the spray
handle. Lock the spray handle
with locking device and turn the
start/stop switch to position „0“.
Let the machine cool off for at
least 3 minutes!
The machine must be placed in
a room where it is not exposed
to frost.
Never start the cleaner without
water supply. Even a short
water deficiency can damage
the sleeves of the pump.
Operation
Avoid damage to the electric
cables such as running over
by a car, squeezing, pull, knots
etc. and keep them away from
sharp or hot objects.
Avoid damage to the high
pressure hose such as running
over by a car, squeezing, pull,
knots/kinks etc. and keep it
away from oil and sharp or hot
objects, as such may cause the
hose to burst.
The cleaner can be used in
zones classified as ZONE 2.
Page 4

Important! Never use the
machine in an environment
where there could be a danger
of explosion (according to EN-
50014).
Important! When the system
has been in operation and
thereafter stopped, there will
still be a working pressure in
the pipeline and high pressure
hoses. Therefore you should
pay special attention to the
following:
• Never dismount the high
pressure hose from the
machine during operation.
Disconnect the machine,
close the shut-off cock and
relieve the high pressure
hose of pressure prior to
dismounting.
• Never dismount the high
pressure hose from the outlet
point before it has been
securely closed and the high
pressure hose has been
relieved of pressure.
• Prior to any service
interference in the machine
it should be disconnected
and the system relieved of
pressure by activating the
trigger of the spray handle.
Repair and Maintenance
Only carry through the
maintenance operations
described in the operating
instructions. Only use original
spare parts.
Do NOT make any technical
modifications to the high
pressure washer.
Warning! High pressure
hoses, nozzles and couplings
are important for the safety
when operating the machine.
Only use the high pressure
hoses, nozzles and couplings
prescribed by below!
For major repairs, please
contact your nearest WSS
service organisation.
Mains power connection
Check the nominal voltage
of the high pressure washer
before connecting it to the
electricity supply.
Check that the voltage stated
on the model tag corresponds
to your mains voltage.
A circuit breaker must be
placed in the immediate vicinity
of the machine.
We recommend you to connect
the machine to a power source
with a Residual Current Device
(RCD) which will disconnect
the power supply if the leakage
current exceeds 30 mA for 20
milli seconds.
Only connect to an approved
socket with earth connection.
Only connect the machine to an
electrical installation made by
an qualified electrician.
The insulation of the electric
cable should be quite faultless
and without any cracks.
If you are in doubt about the
the mains power connection,
please contact a qualified
electrician.
Revision date: 02/2008
EN
Note: If using another cable it
must be earthed and connected
through the plug to the earth
cable of your supply network
in accordance with prescribed
safety regulations.
Always use a cable similar
to the one mounted on the
machine.
Check cables before usage. Do
not use damaged cables.
Only let a qualified electrician
replace the electric cable.
Safety Devices
Safety Valve
The pressure side of the high
pressure pump is fitted with a
safety valve. This valve leads
the water back to the suction
side of the pump when the
spray handle is closed or if a
nozzle is blocked.
The safety valve is adjusted
and sealed by the producer.
THIS ADJUSTMENT MUST
NOT BE CHANGED !
Motor protection
The motor features an
overcurrent protection and
built-in thermal switches for
protection of motor against
overloading. In the event of
increased power consumption
(maloperation), the current for
the motor will automatically be
cut out.
Page 5
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

Revision date: 02/2008 Page 6

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

Revision date: 02/2008 Page 7

EN
3.3 Wall mounting
645
UNO BOOSTER:
Only mount the machine on a
solid wall construction suited for
the mounting of a machine. I.e.
a concrete or brick wall. If the
machine is not mounted verti-
cally, the oil level cannot be
read correctly. When mounting
the machine you should
therefore compensate for a
lopsided wall to make sure that
the wall bracket is placed in a
vertical position.
3.4 Water connection
1 Max. water inlet temp.: 70°C
The water connection is
made through a flexible hose
connected to the quick coupling
on the water inlet (1) of the
machine.
The connection can be made
to a water supply network or an
internal water supply. A shut-
off cock should be mounted
on the water supply network
in the immediate vicinity of the
machine.
Revision date: 02/2008
190
Do not mount the machine
on a wall where it will cause
disturbances in neighbouring
rooms (canteens, offices etc.).
DUO BOOSTER:
Place the machine on a plane
floor.
Machine feet have been
mounted under the machine.
These must be adjusted so that
the machine stands stable.
Max. water pressure: 10 bar
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
internal filter of the machine
(for further connection data see
section 8 Technical data).
If mounting the by-pass hose,
the water inlet temperature can
be raised to 80°C. ONLY do
this if there is a separate water
supply (contact WSS)
distributor).
Clean the water inlet filter (1)
once a month.
Page 8
 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.

Revision date: 02/2008 Page 9

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

pressure hose directly to the
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).

Revision date: 02/2008 Page 10

 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

pressure hose directly to the
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.

Revision date: 02/2008 Page 11

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.

Revision date: 02/2008 Page 12

 EN

4.1.2 High pressure hose -

to outlet point Pipeline, max. length:
(continued)
UNO BOOSTER
Ø12 x 1,5 - max. 50 m
Ø15 x 1,5 - max. 180 m
Ø18 x 1,5 - max. 500 m
DUO BOOSTER
Ø15 x 1,5 - max. 25 m
Ø18 x 1,5 - max. 120 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)

Revision date: 02/2008 Page 13

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

To be attached to the quick

coupling of the high pressure
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

To be attached to the quick

coupling of the high pressure
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.

Revision date: 02/2008 Page 14

 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).

Revision date: 02/2008 Page 15

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.

Revision date: 02/2008 Page 16

 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.

Revision date: 02/2008 Page 17

5 Applications and methods
5.1 General Information Efficient high pressure cleaning
is achieved by following a few
guidelines, combined with your
own personal experience of
specific cleaning tasks.
Accessories and detergents,
when correctly chosen, can
5.1.1 Soaking Incrusted or thick layers of dirt
can be loosened or softened up
by a period of soaking. This is
for example an ideal method
within cargo hold cleaning or
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
should be applied onto dry
surfaces so that the chemical
product is in direct contact with
the dirt. Detergents are applied
from bottom to top, for example
on a bulkhead, in order to
5.1.3 Temperature Detergents are more effective at
higher temperatures. Greases,
oils and fats can be broken
down more easily at higher
temperatures also. Proteins can
5.1.4 Mechanical Effect In order to break down tough
layers of dirt, additional
mechanical effect may be
required. Special lances and
5.1.5 High Water Flow or High pressure is not always the
High Pressure best solution and high pressure
may damage surfaces. The
cleaning effect also depends
upon water flow. Pressure levels
of around 100 bar may be
Revision date: 02/2008
increase the efficiency of your
pressure washer. Here is some
basic information about
cleaning.
the product coat the dirty
surfaces for around 30 minutes
before pressure washing. The
result will be a much quicker
high pressure cleaning process.
avoid “super clean” areas,
where the detergent collects in
higher concentration and
streams downwards. Let the
detergent react several minutes
before cleaning off.
be cleaning at temperatures of
around 60°C. Oils, pollution and
grease can be cleaning
between 70° and 90° C (HPC66
max. 85°C).
rotary or wash brushes offer
this supplementary effect that
cuts through dirt. Use a brush to
cut through e.g. traffic film.
sufficient for vehicle cleaning (in
association with hot water).
Higher flow levels give the
possibility to rinse and flush
away large amounts of dirt
easily.
Page 18
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

Task Accessories Method

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.

Revision date: 02/2008 Page 19

5.2.3 Engine room and other heavy duty cleaning

Task Accessories Method

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.

Revision date: 02/2008 Page 20

6 Maintenance
It applies to the most exposed
components that a minimum
of maintenance ensures a
prolonged and problem-free
operation. Therefore it will be
a good idea to make a habit of
the following:
Prior to attaching the water
hose and the high pressure
hose, the quick couplings
6.1 Oil If the oil level in the oil level
indicator (5) should drop below
the minimum marking, send for
a WSS service technician as
soon as possible.
6.2 Water filter
1 filter (fine) is fitted at the water
UNO BOOSTER DUO BOOSTER
Revision date: 02/2008
EN
should be cleaned of dust and
sand.
Prior to attaching the spray
lance or other accessories to
the spray handle, the machine
should be started and the quick
coupling cleaned of dust and
sand.
PROTECT THE
ENVIRONMENT
Waste oil and oil sludge must
be removed as laid down in the
instructions.
To avoid debris entering the
high pressure pump, a 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.
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.
Page 21
EN
6.3 Cleaning of high A clogging up in the nozzle
pressure nozzle causes a pump pressure which
is too high, and a cleaning is
immediately
required.
6.4 Disposable waste This high pressure washer
consists of parts which can
affect the invironment when
thrown away. Parts that can
pollute are as follows:
Oil, painted/zinc-coated parts,
plastics/plastic-coated parts.
Therefore, it is important to
follow the laws concerning
Revision date: 02/2008
1. Stop the cleaner and detach
the spray lance.
2. Clean the nozzle.
IMPORTANT: ONLY use the
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.
the removal of polluting and
dangerous materials when
replacing spare parts or
disposing of high pressure
washer.
It is recommended that you
bring the rejected parts to
waste disposal areas or
recycling plants that are
approved for the destruction of
these types of materials.
Page 22
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

Revision date: 02/2008 Page 23

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.

Revision date: 02/2008 Page 24

8 Technical Data
Model
Pump pressure 1)
Water volume, min./max. pressure
Water tank, volume
Water connection:
Max. pressure, inlet water
Min. pressure, inlet water
Max. temperature, inlet water
Spray lance:
Nozzle type, h.p./l.p.
Thrust, max.
Pipeline, max. length
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
guaranteed for 12 months from
date of purchase (purchase
receipt must be presented) on
the following conditions:
• that defects are attributable
to flaws or defects in
materials or workmanship.
(Usual wear and tear as well
misuse are not covered
by the guarantee).
• that repairs have not been
carried out or attempted
by other than ALTO-trained
service staff.
EN
UNO BOOSTER DUO BOOSTER
bar 160 160
l/min 19.1/17.3 19.1-38.3/17.3-34.6
liter 3 7.5
bar 10 10
bar 1,0 1,5
°C 70 (80, see section 3.4) 70 (80, see section 3.4)
06/30 06/30
N/kp 47/4,8 47/4,8
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
• that only original Any illegitimate guarantee
accessories have been repair will be invoiced. (I.e.
applied. malfunctions due to causes
• that the product has not mentioned in section “7.0
been exposed to abuse such Trouble shooting” of the
as knocks, bumps or frost. instruction manual).
• that the instructions in the
manual have been carefully
observed.
A warranty repair comprises the
replacement of defective part
but it does not cover freigh
packaging charges. Besides we
refer to national Sale of Goods
Act.
Revision date: 02/2008 Page 25
 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

ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund

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,

ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund ALTO Danmark A/S, Industrikvarteret, DK-9560 Hadsund

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:
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
Se han utilizado las siguientes (partes/cláusulas de) normas y
especificaciones técnicas nacionales:
IEC 60335-2-79
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
55014,
EEN 55014-2, EN 61000-3-2, EN 61000-3-3, prEN 61000-3-11
Sono stati utilizzati i seguenti standard (parti/clausole) tecnici nazionali:
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

Revision date: 02/2008 Page 26

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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

UNO/DUO-BOOSTER_GB02 2
 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

UNO/DUO-BOOSTER_GB01 3
 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.

UNO/DUO-BOOSTER_GB01 4
 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.

UNO/DUO-BOOSTER_GB01 5
 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

UNO/DUO-BOOSTER_GB01 6
 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

UNO/DUO-BOOSTER_GB01 7
 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.

UNO/DUO-BOOSTER_GB02 8
 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

UNO/DUO-BOOSTER_GB02 9
 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

UNO/DUO-BOOSTER_GB02 10
 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.

UNO/DUO-BOOSTER_GB02 11
 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.

UNO/DUO-BOOSTER_GB02 12
 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

UNO/DUO-BOOSTER_GB02 13
 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.

UNO/DUO-BOOSTER_GB02 14
 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.

UNO/DUO-BOOSTER_GB02 15
 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.

UNO/DUO-BOOSTER_GB02 16
 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

UNO/DUO-BOOSTER_GB02 17
 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.

UNO/DUO-BOOSTER_GB02 18
 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.

UNO/DUO-BOOSTER_GB02 19
 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

UNO/DUO BOOSTER_GB01 21
 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

UNO/DUO BOOSTER_GB01 22
 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

UNO/DUO BOOSTER_GB01 23
 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.

UNO/DUO BOOSTER_GB01 24
 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.

UNO/DUO BOOSTER_GB01 25
 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.

UNO/DUO BOOSTER_GB01 26
 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.
&

UNO/DUO BOOSTER_GB01 27
 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.

UNO/DUO BOOSTER_GB01 28
 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.

UNO/DUO BOOSTER_GB01 29
 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

UNO/DUO BOOSTER_GB01 30
 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.

UNO/DUO BOOSTER_GB01 31
 Service / Repair E
ERGO 3000

UNO/DUO BOOSTER_GB01 32
 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.

UNO/DUO-BOOSTER_GB02 33
 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.

UNO/DUO-BOOSTER_GB02 34
 Wiring Diagram G
UNO BOOSTER BASIC 3~, Y
with/without Options

UNO/DUO-BOOSTER_GB02 35
 Wiring Diagram G
UNO BOOSTER EXTENDED 3~, Y
with/without Options

UNO/DUO-BOOSTER_GB02 36
 Wiring Diagram G
UNO BOOSTER BASIC 3~, ∆
with/without Options

UNO/DUO-BOOSTER_GB02 37
 Wiring Diagram G
UNO BOOSTER EXTENDED 3~, ∆
with/without Options

UNO/DUO-BOOSTER_GB02 38
 Wiring Diagram G
UNO BOOSTER EXTENDED 1~
with/without Options

UNO/DUO-BOOSTER_GB02 39
 Wiring Diagram G
DUO BOOSTER BASIC 3~, Y
with/without Options

UNO/DUO-BOOSTER_GB02 40
 Wiring Diagram G
DUO BOOSTER BASIC 3~, Y
with/without Options

UNO/DUO-BOOSTER_GB02 41
 Wiring Diagram G
DUO BOOSTER EXTENDED 3~, Y
with/without Options

UNO/DUO-BOOSTER_GB02 42
 Wiring Diagram G
DUO BOOSTER EXTENDED 3~, ∆
with/without Options

UNO/DUO-BOOSTER_GB02 43
 Wiring Diagram G
DUO BOOSTER EXTENDED 1~
with/without Options

UNO/DUO-BOOSTER_GB02 44