Nilfisk-ALTO POSEIDON 4 Series Service Manual
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Nilfisk-ALTO POSEIDON 4 Series Service Manual

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POSEIDON 4
Service Manual

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Summary of Contents for Nilfisk-ALTO POSEIDON 4 Series

  • Page 1 POSEIDON 4 Service Manual...
  • Page 2 ”Service Manual” and ”Technical Service Bulletin” should be available at the workshop, where the repairs are carried out. It is not permitted to give them to third parties. Use original Nilfisk-ALTO spare parts only. SM_POSEIDON 4_en_Ver.1.0_08.2012...

  • Page 3: Table Of Contents

    Safety instructions Technical data 6 -10 Construction 11 -12 Function 13 -15 Troubleshooting 16 -17 Service / Repair 18 -30 Adjustment / Test Wiring diagrams 32-34 Special tools / Spare parts...
  • Page 4 Index A. Safety instructions 5 ..B. Technical data 6 ..C. Constrution 11 ..D. Function 13 ..E. Troubleshooting 16 ..F. Service / Repair -Indification 18 ..-Regular maintenance 18 ..-Chassis 19 ..-Motor-pump removal 19 ..-Injector 21 ..

  • Page 5: Safety Instructions

    Safety instructions For your own safety Observe valid safety regulations for electrical equipment. In particular, observe the following regulations: IEC 60335-2-79 EN 60335-2-79 Additionally: Also see national regulations Before using the cleaner, always read the ”Operators Manual” and Repair work should be carried keep it readily available.

  • Page 6: Technical Data

    Technical data POSEIDON 4-28 POSEIDON 4-28 POSEIDON 4-28 POSEIDON 4-28 POSEIDON 4 *EU* *EXP* XT *EU* XT *EXP* 230/1/50 220/1/60 230/1/50 220/1/60 Item no. → 301002900 301002901 301002902 301002903 Technical Data ↓ Pump: Pressure @ Cylinder Head (bar) Pressure @ Outlet (bar) Pressure @ Gun (bar) Pressure cut off / stand by @ Cylinder Head (bar) Flow.Qiec (i/min)
  • Page 7 Technical data POSEIDON 4-30 POSEIDON 4-30 POSEIDON 4-29 POSEIDON 4-30 POSEIDON 4 *EU* *ZA* *EXP* XT *EU* 230/1/50 230/1/50 220/1/60 230/1/50 Item no. → 301002904 301002906 301002907 301002910 Technical Data ↓ Pump: Pressure @ Cylinder Head (bar) Pressure @ Outlet (bar) Pressure @ Gun (bar) Pressure cut off / stand by @ Cylinder Head (bar) Flow.Qiec (i/min)
  • Page 8 Technical data POSEIDON 4-28 POSEIDON 4-30 POSEIDON 4-29 POSEIDON 4-36 POSEIDON 4 XT*GB* XT *ZA* XT *EXP* *EU* 230/1/50 230/1/50 220/1/60 400/3/50 Item no. → 301002911 301002912 301002913 301002914 Technical Data ↓ Pump: Pressure @ Cylinder Head (bar) Pressure @ Outlet (bar) Pressure @ Gun (bar) Pressure cut off / stand by @ Cylinder Head (bar) Flow.Qiec (i/min)
  • Page 9 Technical data POSEIDON 4-36 POSEIDON 4-35 POSEIDON 4-36 POSEIDON 4-36 POSEIDON 4 *EXP* *JP* XT *EU* XT *EXP* 220/440/3/60 200/3/50 400/3/50 220/440/3/60 Item no. → 301002915 301002916 301002918 301002919 Technical Data ↓ Pump: Pressure @ Cylinder Head (bar) Pressure @ Outlet (bar) Pressure @ Gun (bar) Pressure cut off / stand by @ Cylinder Head (bar) Flow.Qiec (i/min)
  • Page 10 Technical data Poseidon 4-36 Poseidon 4-36 XT POSEIDON 4-29 POSEIDON 4-31 POSEIDON 4 *NO* *NO* XT *AU* *GB* 230/400/3/50 230/400/3/50 230/1/50 230/1/50 Item no. → 301002922 301002925 301003110 301003184 Technical Data ↓ Pump: Pressure @ Cylinder Head (bar) Pressure @ Outlet (bar) Pressure @ Gun (bar) Pressure cut off / stand by @ Cylinder Head (bar) 11,7...

  • Page 11: Construction

    Construction Hose Reel Ergo 2000 gun Handle(crank) Lance holder top TurboHammer 3000 Detergent Valve Flexo Power 3000 ON / OFF switch Water inlet Lance holder bottom Fig.C.1: POSEIDON 4 - XT POSEIDON 4 variants : 1 phase: 4-28 / 4-28XT* / 4-29* / 4-29XT* / 4-30* / 4-30XT* / 4-31* 3 phase: 4-35* / 4-36* / 4-36XT* XT vs.
  • Page 12 Construction Hose reel XT Model Hook for electric cord XT Model Light alloy frame Detergent tank Name plate Fig.C.3: Rear view Complete machine XT Model Hose for pump oil view Pump oil plug Pump housing Water inlet with strainer End switch Aut. Start/stop Unloader outlet Fig.C.9: Pump head (Valve block)

  • Page 13: Function

    Function Functional-block diagram Functional-block diagram 1~ Power Motor (M1) Water Strainer HP-Pump Injektor Spray device Detergent Dt.Valve Fig. D.1: Functional diagram POSEIDON 4 (1~) Explanation for functional diagram (Refer to technical data part B and wiring diagrams part H) Preconditions: -The high pressure cleaner is connected to adequate water and power supply.
  • Page 14 Function Functional-block diagram 3~ Power Motor (M1) Water Strainer HP-Pump Injektor Spray device Dt.Valve Detergent Fig. D.2: Functional diagram POSEIDON 4 (3~) Explanation for functional diagram (Refer to technical data part B and wiring diagrams part H) Preconditions: -The high pressure cleaner is connected to adequate water and power supply. Main switch S1 in ”OFF”...
  • Page 15 Function Principal drawing The schematic drawing of the pump head in (Fig.D.3) is made to get a better understanding of the function. NOTE ! In Fig,D.3 the pump head is shown with a two-way easy start valve, which is the layout for all the single phase machines, whereas the three phase machines are without the valve.

  • Page 16: Troubleshooting

    Troubleshooting Fault Cause Remedy Pressure drop - Air in the system.  Vent the system by operating the spray gun several times at short intervals .If necessarly operate the cleaner for a short time without the High pressure hose connected. - High pressure nozzle ...
  • Page 17 Troubleshooting Fault Cause Remedy When the cleaner is switched  The main voltage is too low  Have the electrical on the motor buzzes without or there is a phase failure connections checked. starting. (3 ph model).  The pump is blocked or ...

  • Page 18: Service / Repair

    Service / Repair Data plate Fig.F.1: Data Plate Fig.F.2: Data Plate - Internal •Identify the machine version at the •Internal data plate is situated on the fan dataplate situated on the back of the cover. machine. Regular maintenance NEW ! Fig.F.3: Water inlet filter - Cleaning Fig.F.4: Oil level Maintenance Plan...

  • Page 19: Chassis

    Service / Repair Chassis 6x Torx Fig.F.5: Cover Screws - Removal Fig.F.6: Oil hose Before doing any repair work, remove the •Remove oil level hose from it`s bracket, cover by unscrewing the 6 torx screws on entering the cleaner form the bottom of the the backside of the cleaner.
  • Page 20 Service / Repair Motor/pump removal Fig.F.9: Clamp for micro switch housing Fig.F.10: Motor suspension •Remove the clamp using a pair of nose •The motor/pump unit is mounted in 4 pliers. brackets. •Note the position of the clamp. Fig.F.11: Motor bracket Fig.F.12: Motor/pump remove •Dismount the 4 motor brackets using a torx •When the 4 screws are loosened, the...

  • Page 21: Injector

    Service / Repair Chemical injector Fig.F.13: Hose tail for chemical injector Fig.F.14: Chemical injector—complete •Loosen the hose tail using a 10mm wrench •The chemical injector consists of: and remove the complete chemical injector. Hose tail with seat. O-ring inside the hose tail. •After repair tighten the hose tail according Ball.

  • Page 22: Pressure Regulation

    Service / Repair Pressure regulation Fig.F.17: Pressure regulation Fig.F.18: Pressure regulation •Remove the pressure regulation by using a •Inspect the pressure regulation and the 21mm wrench. valve seat for damages. Fig.F.19: Pressure valve seat Fig.F.20: Pressure regulation •The pressure regulation valve seat can be •Pressure regulation disassembled.

  • Page 23: Control Piston

    Service / Repair Control piston Fig.F.21: Control piston Fig.F.22: Control piston and start/stop switch •Remove control piston using a 17mm •By reassembling be aware of the O-ring wrench and check for damages and wear. between brass connector and micro switch •Grease the O-rings before reassembling.
  • Page 24 Service / Repair Valves Fig.F.25: Pressure valves Fig.F.26: Plug for valves •As shown on the cut-view the pressure •Loosen the three plugs retaining the valve is kept in place by a plug. pressure valves and pull out the valves by means of e.g.

  • Page 25: Piston Guides And Seals

    Service / Repair Valves Fig.F.29: Valve replacement Fig.F.30: Valve replacement •Use e.g. a screw with coarse threads to •Grease o-rings lightly before reassembly. pull out the valves. •Press down firmly with your finger. •Tighten plug (pressure valves) according to •Beware not to damage the seals, if they don`t need replacement.
  • Page 26 Service / Repair Piston Guides And Seals Fig.F.33: Piston guide removal Fig.F.34: Piston guide with extractor •If the piston guides can`t be removed by •Note the position of the internal extractor. hand, use an internal extractor as shown, •Replace the complete piston seal kit. (Bahco 4521N-F).

  • Page 27: Wobble Disc Housing

    Service / Repair Wobble Disc Housing Fig.F.37: Woble disc housing Fig.F.38: Woble disc housing Removal of wobble disc housing: Assembly of Wobble disc housing: •With pump head removed, loosen the four •Replace two of the screws M8x25 with hexagon screws with a 6mm allen key and M8x40 to support the relief of the springs.

  • Page 28: Wobble Disc

    Service / Repair Pistons and oil seals NEW ! Fig.F.41: Oil seal installation Fig.F.42: Spacer rings for seals Using a proper tool (see picture) or a • By assembly note that the pin of the  suitable pipe carefully tap the new oil seal spacer ring must be placed in the cylinder in place.

  • Page 29: Motor Fan

    Service / Repair Motor fan Fig.F.44: Fan removal. Fig.F.45: Fan removal. • Use a suitable puller to remove the lock • Use two screwdrivers to press off the fan. ring • In some cases the fan is stuck on the motor shaft and must be destroyed to get loose.

  • Page 30: Torque Settings

    Service / Repair Torque Settings Name Size Torque Page* Regulation Safety Block M18(1,0) 15 Nm Plug (Valves) M18(1,0) 50 Nm Union nut (Start/Stop control piston) M12(1,25) 15 Nm Cartridge easy start valve M12(1,0) 10 Nm Screw (Pump head) M12(1,0)x70 50 Nm Screw (Wobble housing) M8(1,25)x25 25 Nm...

  • Page 31: Adjustment / Test

    Adjustment / Test Adjustment of cut off pressure Fig.G.1: Pressure regulation Fig.G.2: Pressure adjustment Install test pressure gauge 1206358 on • The cut off pressure is adjusted on the water machine outlet. regulation. Open the regulation fully. • Use a 3mm allen key and a 10mm spanner. Close untill machine has reached the re- •...

  • Page 32: Wiring Diagrams

    Wiring diagrams SM_POSEIDON 4_en_Ver.1.0_08.2012...
  • Page 33 Wiring diagrams SM_POSEIDON 4_en_Ver.1.0_08.2012...
  • Page 34 Wiring diagrams SM_POSEIDON 4_en_Ver.1.0_08.2012...

  • Page 35: Special Tools / Spare Parts

    Special Tools / Spare Parts Part Number Description Remarks Special Tools 1206358 Test Pressure Gauge Adjustment cut-off pressure 1220352 Impact piercer Valve seat removel Puller (two legged) Wobble disc removel Additional Materials 41455 Grease (-15 C to +130 C) Valve grease 909100414 Pump oil Rotra THT...
  • Page 36 Notes SM_POSEIDON 4_en_Ver.1.0_08.2012...
  • Page 37 Nilfisk - ALTO Division of Nilfisk - Advance A/S Industrivej 1 9650 Hadsund Denmark www.nilfisk-alto.com...

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