Nilfisk-ALTO POSEIDON 4 Series User manual

Service Manual
POSEIDON 4

SM_POSEIDON 4_en_Ver.1.0_08.2012
Preface
This service manual contains detailed description of the main repair work on the cold high
pressure washer POSEIDON 4.
Repair work requires a suitable working place with the necessary water and power supply.
If operating errors are evident, draw the customers attention to the ”Operators Manual”.
A fault in the high pressure washer can have several causes as described in the section on
troubleshooting.
Refer to the illustrated ”Spare Parts Catalogue” during repairs. It shows the assembly position
and the sequence in which the individual components should be assembled.
See ”Technical Service Bulletin” (TSB) sheets. They include information on technical
modifications that have been made after this repair manual was made.
”Technical Service Bulletin” sheets are also valid as a supplement to the spare parts list until
publication of a new edition.
”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.

A.
B.
C.
D.
E.
F.
G.
H.
I.
Special tools /
Spare parts 35
Wiring diagrams 32-34
Adjustment / Test 31
Service / Repair 18 -30
Troubleshooting 16 -17
Function 13 -15
Construction 11 -12
Technical data 6-10
Safety instructions 5

Index
4
SM_POSEIDON 4_en_Ver.1.0_08.2012
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....
-Pressure regulation 22....
-Control piston 23....
-Easy start valve 23....
-Pump valves 24....
-Piston guides and seals 25....
-Wobble disc housing 27....
-Pistons and oil seals 27....
-Wobble disc 28....
-Motor fan 29....
-Torque settings 30....
G. Adjustment / Test
-Operating / cut-off pressure 31....
H. Wiring diagrams 32....
I. Special tools / Spare parts 35....

A
SM_POSEIDON 4_en_Ver.1.0_08.2012
Safety instructions
5
For your own safety
ESD measures
(electrostatic discharge)
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
keep it readily available.
Only allow the high pressure
cleaner to be used by persons
who have been trained in its use
and who have been explicitly aut-
horized to use it.
Repair work should be carried
out by persons instructed in
electrical installations or by
trained electricians only.
Take the following ESD precautions before carrying out any
repairs to the electronics:
 Touch the earth conductor before repairing the cleaner
( to discharge electrostatic charge from your body ).
 Wear wrist band if necassary.
 Use a conductive floor covering or a conductive table cover.
 Never touch the printed circuit board or electronic components
( always hold on to plastic ).
 Transport electronic components in conductive packaging
( e.g. ESD bag ).

B
Technical data
SM_POSEIDON 4_en_Ver.1.0_08.2012 6
POSEIDON 4 POSEIDON 4-28
*EU*
230/1/50
POSEIDON 4-28
*EXP*
220/1/60
POSEIDON 4-28
XT *EU*
230/1/50
POSEIDON 4-28
XT *EXP*
220/1/60
Item no. →301002900 301002901 301002902 301002903
Technical Data ↓
Pump:
Pressure @ Cylinder Head (bar) 130 130 130 130
Pressure @ Outlet (bar)
Pressure @ Gun (bar) 110 110 105 106
Pressure cut off / stand by @ Cylinder Head (bar) 160 140 160 160
Flow.Qiec (i/min) 9,4 10 9,4 9,7
Suction height, dry (m) 0,5 0,5 0,5 0,5
Suction height, primed (m) 1111
Pump type AR 280 AR 280 AR 280 AR 280
Number of pistons 3333
Piston type Painted ceramic Painted ceramic Painted ceramic Painted ceramic
Stroke / Wobble disc angle (mm/deg)
Pump oil type Rotra THT Rotra THT Rotra THT Rotra THT
Oil volume (l) 0,225 0,225 0,225 0,225
Electric:
Electrical data: 230V/1ph/50Hz/
13,2A/3KW
220V/1ph/60Hz/
13A/2,9KW
230/1ph/50Hz/
13,2A/3KW
220V/1ph/60Hz/
13A/2,9KW
Control voltage (volt) XXX
Highvoltage (HV) test (V) 1,5 1,5 1,5 1,5
HV insulation resistance (MΩ) 1111
Earth circuit resistance (Ohm Ω) 0,2 0,2 0,2 0,2
Motor rotational speed [min-1] 1450 1750 1450 1750
Electrical diagram no.
Unit Data
High pressure nozzle NT0400 NT0400 NT0400 NT0400
Max. Inlet temperature (°C) suction 50 50 50 50
Max. Inlet temperature (°C) pressure fed 60 60 60 60
Gun ERGO 2000 ERGO 2000 ERGO 2000 ERGO 2000
Lance type 1 Flexo power Flexo power Flexo power Flexo power
Lance type 2 None None Turbohammer None
Hose DN6 x 10m DN6 x 10m DN6 x 15m DN6 x 10m
Sound power LWA (dB) 89 89 89 89
Impactfactor 2,6 2,6 2,6 2,5
Vibration ISO 5349 ( m/s² ) 0000
Protection Class IPX5 IPX5 IPX5 IPX5
Weight - Machine alone (kg) 37 37 40 40
Size - Machine alone (mm) 1030x400x400 1030x400x400 1030x400x400 1030x400x400

B
Technical data
SM_POSEIDON 4_en_Ver.1.0_08.2012 7
POSEIDON 4 POSEIDON 4-30
*EU*
230/1/50
POSEIDON 4-30
*ZA*
230/1/50
POSEIDON 4-29
*EXP*
220/1/60
POSEIDON 4-30
XT *EU*
230/1/50
Item no. →301002904 301002906 301002907 301002910
Technical Data ↓
Pump:
Pressure @ Cylinder Head (bar) 142 145 144 142
Pressure @ Outlet (bar)
Pressure @ Gun (bar) 128 128 120 129
Pressure cut off / stand by @ Cylinder Head (bar) 175 160 160 160
Flow.Qiec (i/min) 8,6 8,6 9,3 8,6
Suction height, dry (m) 0,5 0,5 0,5 0,5
Suction height, primed (m) 1111
Pump type AR 280 AR 280 AR 280 AR 280
Number of pistons 3333
Piston type Painted ceramic Painted ceramic Painted ceramic Painted ceramic
Stroke / Wobble disc angle (mm/deg)
Pump oil type Rotra THT Rotra THT Rotra THT Rotra THT
Oil volume (l) 0,225 0,225 0,225 0,225
Electric:
Electrical data: 230V/1ph/50HZ/
15A/3,3KW
230V/1ph/50HZ/
15A/3,3KW
220V/1ph/60HZ/
15A/3,3KW
230V/1ph/50HZ/
15A/3,3KW
Control voltage (volt)
Highvoltage (HV) test (V) 1,5 1,5 1,5 1,5
HV insulation resistance (MΩ) 1111
Earth circuit resistance (Ohm Ω) 0,2 0,2 0,2 0,2
Motor rotational speed [min-1] 1450 1450 1750 1450
Electrical diagram no.
Unit Data
High pressure nozzle NT0350 NT0350 NT0370 NT0350
Max. Inlet temperature (°C) suction 50 50 50 50
Max. Inlet temperature (°C) pressure fed 60 60 60 60
Gun ERGO 2000 ERGO 2000 ERGO 2000 ERGO 2000
Lance type 1 Flexo power Flexo power Flexo power Flexo power
Lance type 2 None None None Turbohammer
Hose DN6 x 10m DN6 x 10m DN6 x 10m DN6 X 15m
Sound power LWA (dB) 89 89 89 89
Impactfactor 2,5 2,4 2,5 2,5
Vibration ISO 5349 ( m/s² ) 0000
Protection Class IPX5 IPX5 IPX5 IPX5
Weight - Machine alone (kg) 40 40 40 40
Size - Machine alone (mm) 1030x400x400 1030x400x400 1030x400x400 1030x400x400

B
Technical data
SM_POSEIDON 4_en_Ver.1.0_08.2012 8
POSEIDON 4 POSEIDON 4-28
XT*GB*
230/1/50
POSEIDON 4-30
XT *ZA*
230/1/50
POSEIDON 4-29
XT *EXP*
220/1/60
POSEIDON 4-36
*EU*
400/3/50
Item no. →301002911 301002912 301002913 301002914
Technical Data ↓
Pump:
Pressure @ Cylinder Head (bar) 129 142 144 147
Pressure @ Outlet (bar)
Pressure @ Gun (bar) 105 129 120 116
Pressure cut off / stand by @ Cylinder Head (bar) 150 160 150 175
Flow.Qiec (i/min) 8,6 8,6 8,7 11,7
Suction height, dry (m) 0,5 0,5 0,5 0,5
Suction height, primed (m) 1111
Pump type AR 280 AR 280 AR 280 AR 280
Number of pistons 3333
Piston type Painted ceramic Painted ceramic Painted ceramic Painted ceramic
Stroke / Wobble disc angle (mm/deg)
Pump oil type Rotra THT Rotra THT Rotra THT Rotra THT
Oil volume (l) 0,225 0,225 0,225 0,225
Electric:
Electrical data: 230V/1ph/50HZ/
13A/2,9KW
230V/1ph/50HZ/
13A/3,3KW
220V/1ph/60HZ/
15A/3,3KW
400V/3ph/50HZ/
7,6A/4,2KW
Control voltage (volt)
Highvoltage (HV) test (V) 1,5 1,5 1,5 1,5
HV insulation resistance (MΩ) 1111
Earth circuit resistance (Ohm Ω) 0,2 0,2 0,2 0,2
Motor rotational speed [min-1] 1450 1450 1750 1450
Electrical diagram no.
Unit Data
High pressure nozzle NT0400 NT0350 NT0370 NT0475
Max. Inlet temperature (°C) suction 50 50 50 50
Max. Inlet temperature (°C) pressure fed 60 60 60 60
Gun ERGO 2000 ERGO 2000 ERGO 2000 ERGO 2000
Lance type 1 Flexo power Flexo power Flexo power Flexo power
Lance type 2 Turbohammer Turbohammer Turbohammer None
Hose DN6 X 15m DN6 X 15m DN6 X 15m DN6 x 10m
Sound power LWA (dB) 89 89 89 89
Impactfactor 2,4 2,4 2,3 3,4
Vibration ISO 5349 ( m/s² ) 0000
Protection Class IPX5 IPX5 IPX5 IPX5
Weight - Machine alone (kg) 40 40 40 40
Size - Machine alone (mm) 1030x400x400 1030x400x400 1030x400x400 1030x400x400

B
Technical data
SM_POSEIDON 4_en_Ver.1.0_08.2012 9
POSEIDON 4 POSEIDON 4-36
*EXP*
220/440/3/60
POSEIDON 4-35
*JP*
200/3/50
POSEIDON 4-36
XT *EU*
400/3/50
POSEIDON 4-36
XT *EXP*
220/440/3/60
Item no. →301002915 301002916 301002918 301002919
Technical Data ↓
Pump:
Pressure @ Cylinder Head (bar) 150 132 147 150
Pressure @ Outlet (bar)
Pressure @ Gun (bar) 120 112 119 120
Pressure cut off / stand by @ Cylinder Head (bar) 155 160 175 155
Flow.Qiec (i/min) 11,7 10,7 11,7 11,7
Suction height, dry (m) 0,5 0,5 0,5 0,5
Suction height, primed (m) 1111
Pump type AR 280 AR 280 AR 280 AR 280
Number of pistons 3333
Piston type Painted ceramic Painted ceramic Painted ceramic Painted ceramic
Stroke / Wobble disc angle (mm/deg)
Pump oil type Rotra THT Rotra THT Rotra THT Rotra THT
Oil volume (l) 0,225 0,225 0,225 0,225
Electric:
Electrical data: 220V/440V/3ph/
60HZ/?A/4,2KW
200V/3ph/50HZ/
14,3A/4,2KW
400V/3ph/50HZ/
7,6A/4,2KW
220/440V/3ph/
60HZ/?A/4,2KW
Control voltage (volt)
Highvoltage (HV) test (V) 1,5 1,5 1,5 1,5
HV insulation resistance (MΩ) 1111
Earth circuit resistance (Ohm Ω) 0,2 0,2 0,2 0,2
Motor rotational speed [min-1] 1750 1450 1450 1750
Electrical diagram no.
Unit Data
High pressure nozzle NT0450 NT0475 NT0475 NT0450
Max. Inlet temperature (°C) suction 50 50 50 50
Max. Inlet temperature (°C) pressure fed 60 60 60 60
Gun ERGO 2000 ERGO 2000 ERGO 2000 ERGO 2000
Lance type 1 Flexo power Flexo power Flexo power Flexo power
Lance type 2 None None Turbohammer Turbohammer
Hose DN6 x 10m DN6 x 10m DN6 X 15m DN6 X 15m
Sound power LWA (dB) 89 89 89 89
Impactfactor 3,4 ?3,4 ?
Vibration ISO 5349 ( m/s² ) 0000
Protection Class IPX5 IPX5 IPX5 IPX5
Weight - Machine alone (kg) 40 40 40 40
Size - Machine alone (mm) 1030x400x400 1030x400x400 1030x400x400 1030x400x400

B
Technical data
SM_POSEIDON 4_en_Ver.1.0_08.2012 10
POSEIDON 4 Poseidon 4-36
*NO*
230/400/3/50
Poseidon 4-36 XT
*NO*
230/400/3/50
POSEIDON 4-29
XT *AU*
230/1/50
POSEIDON 4-31
*GB*
230/1/50
Item no. →301002922 301002925 301003110 301003184
Technical Data ↓
Pump:
Pressure @ Cylinder Head (bar) 147 147 131 75
Pressure @ Outlet (bar)
Pressure @ Gun (bar) 120 120 120 ?
Pressure cut off / stand by @ Cylinder Head (bar) 155 155 175 145
Flow.Qiec (i/min) 11,7 11,7 8,6 11,2
Suction height, dry (m) 0,5 0,5 0,5 0,5
Suction height, primed (m) 1111
Pump type AR 280 AR 280 AR 280 AR 280
Number of pistons 3333
Piston type Painted ceramic Painted ceramic Painted ceramic Painted ceramic
Stroke / Wobble disc angle (mm/deg)
Pump oil type Rotra THT Rotra THT Rotra THT Rotra THT
Oil volume (l) 0,225 0,225 0,225 0,225
Electric:
Electrical data: 230/400V/3ph/
50HZ/?A/4,2KW
230/400V/3ph/
50HZ/?A/4,2KW
240V/1ph/50HZ/
14,4A/3,1KW
230V/1ph/50HZ/
13A/2,9KW
Control voltage (volt)
Highvoltage (HV) test (V) 1,5 1,5 1,5 1,5
HV insulation resistance (MΩ) 1111
Earth circuit resistance (Ohm Ω) 0,2 0,2 0,2 0,2
Motor rotational speed [min-1] 1450 1450 1450 1450
Electrical diagram no.
Unit Data
High pressure nozzle NT0475 NT0450 NT0350 NT0600
Max. Inlet temperature (°C) suction 50 50 50 50
Max. Inlet temperature (°C) pressure fed 60 60 60 60
Gun ERGO 2000 ERGO 2000 ERGO 2000 ERGO 2000
Lance type 1 Flexo power Flexo power Flexo power Flexo power
Lance type 2 None Turbohammer Turbohammer None
Hose DN6 x 10m DN6 X 15m DN6 X 15m DN6 x 10m
Sound power LWA (dB) 89 89 89 89
Impactfactor ?3,4 2,4 2,3
Vibration ISO 5349 ( m/s² ) 0000
Protection Class IPX5 IPX5 IPX5 IPX5
Weight - Machine alone (kg) 40 40 40 40
Size - Machine alone (mm) 1030x400x400 1030x400x400 1030x400x400 1030x400x400

Construction C
SM_POSEIDON 4_en_Ver.1.0_08.2012 11
Fig.C2:
POSEIDON 4 Standard
Fig.C.1: POSEIDON 4 - XT
Flexo Power 3000
XT vs. Standard
-Hose Reel
-Hose lenght 15m
-Turbo Hammer Lance
Ergo 2000 gun
Lance holder top
Water inlet
ON / OFF switch
TurboHammer 3000
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*
Handle(crank)
(*) These numbers refer to the theoretical total impact of spraying
water calculated by the formula:
Impact = Q1 x P1 x 0.24 [ N ]
Q1 = l/min. v P1
P1 = Bar
Hose Reel
Lance holder bottom
Detergent Valve

Construction C
SM_POSEIDON 4_en_Ver.1.0_08.2012 12
Pump housing
End switch Aut. Start/stop
Water inlet with strainer
Fig.C.9: Pump head
(Valve block)
Detergent tank
Fig.C.3:
Rear view
Complete machine
XT Model
Hook for electric cord
XT Model
Light alloy frame
Pump oil plug Hose for pump oil view
Unloader outlet
Hose reel
XT Model
Name plate

D
13
SM_POSEIDON 4_en_Ver.1.0_08.2012
Function
Functional-block diagram
HP-PumpStrainer PV Injektor Spray device Water
Power S1
Motor (M1) B4
B3
Detergent Dt.Valve
Fig. D.1: Functional diagram POSEIDON 4 (1~)
Functional-block diagram 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.
Main switch S1 in ”OFF” position.
-There is main voltage to S1.
-Cleaner is still off.
Main switch S1 in ”ON” position.
-Gun closed : The cleaner starts up (if B4 is closed and B3 is closed) until cut-off pressure is
reached => end switch B4 opens => the cleaner stops.
-NOTE ! Static high pressure water between valve block - hose - gun .
-Gun activated: The pressure drops in pressure valve => the end switch B4 is activated =>
the cleaner starts up and runs at working pressure.
-Gun being closed: Working pressure increases to cut-off pressure => end switch opens =>
the cleaner stops.
-Detergent valve: The cleaner running at working pressure and the detergent valve open,
detergent is added by means of the vacuum in the injector to the high pressure water.

D
14
SM_POSEIDON 4_en_Ver.1.0_08.2012
Function
Functional-block diagram 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” position.
-There is main voltage to S1 and K1
-Cleaner is still off.
Main switch S1 in ”ON” position.
-Gun closed : K1 is activated (if B4 is closed and B3 is closed) until cut-off pressure is
reached => end switch B4 opens => K1 disengages => the cleaner stops.
-NOTE ! Static high pressure water between valve block - hose - gun .
-Gun activated: The pressure drops in pressure valve => the end switch B4 closes => K1
engages => the cleaner starts up and runs at working pressure.
-Gun being closed: Working pressure increases to cut-off pressure => end switch opens =>
K1 disengages => the cleaner stops.
-Detergent valve: The cleaner running at working pressure and the detergent valve open,
detergent is added by means of the vacuum in the injector to the high pressure water.
HP-PumpStrainer PV Injektor Spray deviceWater
Power
S1
Motor (M1) B4
B3
Detergent Dt.Valve
K1
Fig. D.2: Functional diagram POSEIDON 4 (3~)

D
15
SM_POSEIDON 4_en_Ver.1.0_08.2012
Function
Fig.D.4: Valve block 1 ~ - Cut Away View
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.
Fig.D.3: Schematic Drawing Pump Head
Pressure outlet
Non-return valve
Dertergent valve
Piston
Easy start valve
End switch
Inlet
Pressure reg. valve
Control piston
Valve pressure
Valve suction
Principal drawing
Pressure reg. valve
Dertergent valve
Pressure outlet Inlet
Control piston
End switch
Easy start valve

E
Troubleshooting
SM_POSEIDON 4_en_Ver.1.0_08.2012 16
Fig. E.1:Troubleshooting 1
Fault Cause Remedy
Pressure drop - Air in the system.
- High pressure nozzle
blocked / worn.
- Pressure control on the
spray lance is not set
correctly.
- Detergent container empty.
- Water inlet temperature
too high.
 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.
 Clean / replace the high
pressure nozzle.
 Set the required working
pressure.
 Change container or close
detergent valve.
 See technical data part ”B”.
Pressure
fluctuations
- Lack of water
- Water inlet hose is too long
or its cross-section too
small.
- Lack of water caused by
blocked water filter.
- Lack of water because
max. permissible suction
height has not been
heeded.
- Pump sucks in air
(suction mode)
 Open water tap.
 Use specified water inlet
hose(Refer to user manual).
 Clean the water filter in the
water connection.
(Never work without water
filter).
 See technical data part ”B”
 Check that the suction set
is air tight.
The motor does not start when
the cleaner is switced on.
- The plug is not inserted
properly, i.e. there is no
current.
- The main fuse is switced off.
 Check the plug, lead and
switch.
If necessary have them
replaced by a trained
electrician.
 Switch on the main fuse.

E
Troubleshooting
SM_POSEIDON 4_en_Ver.1.0_08.2012 17
Fault Cause Remedy
When the cleaner is switched
on the motor buzzes without
starting.
 The main voltage is too low
or there is a phase failure
(3 ph model).
 The pump is blocked or
frozen.
 Incorrect cross-section or
lenght of the extension lead.
 Have the electrical
connections checked.
 Pump needs service
(see part ”F”).
 Use lead with correct cross
section and length.
The motor switches off.  The overload protection has
been activated due to
overheating or overloading
of the motor.
 High pressure nozzle is
dirty.
 Check that the main voltage
and the cleaner voltage are
the same.
Switch off the cleaner and
allow it to cool for at least
3 minutes.
 Change the high pressure
nozzle.
Cleaner starts / stops by itself.  Leakage on high pressure
side.
 Locate the leak and repair
it.
No detergents drawn in.  Injector is dirty or suction
hose is blocked.
 Detergent container empty.
 The cap on the nozzle is
not set at low pressure.
 Clean.
 Top up/change the
container.
 Turn cap of the
FlexoPower nozzle towards
”CHEM” up to the stop.

F
SM_POSEIDON 4_en_Ver.1.0_08.2012
Service / Repair
18
Maintenance Plan Weekly As required
Cleaning water inlet filter
Checking pump oil level
Changing pump oil By pump repairs
Fig.F.4: Oil level
Regular maintenance
Data plate
•Identify the machine version at the
dataplate situated on the back of the
machine.
•Internal data plate is situated on the fan
cover.
Fig.F.1: Data Plate Fig.F.2: Data Plate - Internal
Fig.F.3: Water inlet filter - Cleaning
NEW !

F
SM_POSEIDON 4_en_Ver.1.0_08.2012
Service / Repair
19
Before doing any repair work, remove the
cover by unscrewing the 6 torx screws on
the backside of the cleaner.
Fig.F.5: Cover Screws - Removal
Chassis
Fig.F.6: Oil hose
•Remove oil level hose from it`s bracket,
entering the cleaner form the bottom of the
machine.
Fig.F.7: pump head with connections Fig.F.8: Bracket for micro switch
6x Torx
Motor/pump removal
•To dismount the pump head.
•Remove all connections: micro switch and
detergent hose.
•Remove the HP hose (plus-version)
•Remove the bracket for micro switch using
a torx 20 screwdriver

F
SM_POSEIDON 4_en_Ver.1.0_08.2012
Service / Repair
20
Motor/pump removal
Fig.F.9: Clamp for micro switch housing
Fig.F.11: Motor bracket Fig.F.12: Motor/pump remove
•Remove the clamp using a pair of nose
pliers.
•Note the position of the clamp.
•Dismount the 4 motor brackets using a torx
20 screwdriver.
•The motor/pump unit is mounted in 4
brackets.
Fig.F.10: Motor suspension
•When the 4 screws are loosened, the
motor/pump unit can be removed from the
frame.