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Poseidon

Service Manual
1
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A TechnicalData

B Construction

C Function

D Trouble-shooting

Index
Poseidon E Service/Repair

F Adjustment/Test

G WiringDiagrams

H SparePartsProposal

I SpecialInformation

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Technical Data A

Poseidon 1200
Primary data Unit General Nominal values Tolerances
Voltage VAC 200 240 400 415 440 440 +6/-10%
Frequency Hz 50 50 50 50 60
Motor coupling
Number of phases Pce. 3 3 3 3
Power consumption A 12 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 6.7
Axel power kW 5.5
Revolutions Min-1 1440 1420-1470
Control voltage VAC 200 240 400 415 440 440 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec 20
Bypass time manual Min 5
Water volume, high-pressure l/min 17.6
Water volume, low-pressure l/min 19.1
Machine's pressure gauge Bar 175 +-8.5%
Pump pressure, high-pressure Bar 158
Pressure, h-p pump outlet Bar 152
Opening pressure, pump outlet Bar 185 +-7
Bypass pressure Bar 11 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C 85
Max. water inlet pressure Bar 10
Reaction force, max. N 54
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Pump oil 100

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Technical Data A

Poseidon 1280
Primary data Unit General Nominal values Tolerances
Voltage VAC 200 240 400 415 440 440 +6/-10%
Frequency Hz 50 50 50 50 60
Motor coupling
Number of phases Pce. 3 3 3 3
Power consumption A 13 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 8.3
Axel power kW 6.5
Revolutions Min-1 1440 1420-1470
Control voltage VAC 200 240 400 415 440 440 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec. 20
Bypass time manual Min 5
Water volume, high-pressure l/min 18.6
Water volume, low-pressure l/min 20.3
Machine's pressure gauge Bar 195 +-8.5%
Pump pressure, high-pressure Bar 178
Pressure, h-p pump outlet Bar 170
Opening pressure, pump outlet Bar 200 +-7
Bypass pressure Bar 12 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C 85
Max. water inlet pressure Bar 10
Reaction force, max. N
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Alphasyn T 150

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Technical Data A

Poseidon 720
Primary data Unit General Nominal values Tolerances
Voltage VAC 230 +6/-10%
Frequency Hz 50
Motor coupling 3
Number of phases Pce. 1
Power consumption A 12 +-1.5
High voltage KV 2.4 in 2 sec.
Leakage current mA 0.75
Resistance in ground circuit Ohm 0.2
Absorption power kW 2.9
Axel power kW 2.1
Revolutions Min-1 1430 1420-1470
Control voltage VAC 230 +-10%
Signal voltage microprocessor VAC 5 +-10%
IP classification 45
Bypass time auto start/stop Sec 20
Bypass time manual Min 5
Water volume, high-pressure l/min 11.5
Water volume, low-pressure l/min 12.5
Machine's pressure gauge Bar 105 +-8.5%
Pump pressure, high-pressure Bar 101
Pressure, h-p pump outlet Bar 93
Opening pressure, pump outlet Bar 125 +-7
Bypass pressure Bar 10.5 +-4
Suction capacity Bar 0.17
Suction height, primed m 3
Max. water inlet temperature °C 85
Max. water inlet pressure Bar 10
Reaction force, max. N 54
Acoustic pressure level dBA 75.4
Oil volume Litre 0.5
Oil type Pump oil 100

Poseidon_GB01 3
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Construction B
Frame
The frame is built of Ø25mm steel pipes. One nozzle can be stored on each side of the machine.

2, Ø250mm wheels and 1, Ø100mm swivel wheel are mounted to the frame.

A bent bar is attached to the front of the frame to protect hose attachments. The bar is also used for lifting the
machine both manually and by crane.

The back bar is equipped with fixtures for mounting hose reel, a U-bar for placing nozzles, and winding reel for
electrical cable.
The steering handle is made of plastic.

Cabinet
The cabinet is made of vacuum-shaped plastic.
On the cabinet’s top side there is room for storing small auxiliary articles.
All hoses are connected through the hole at the front of the cabinet.

Motor/pump
The motor/pump unit is attached to the frame with four taptite screws in the electric motor’s stator. This
way the pump can be accessed from the front of the machine, and those parts of the pump susceptible
to wear are easily serviced.

The pump is a 4-cylinder axial piston pump with a wobble disc system and solid ceramic pistons. Suction
and pressure valves are made of stainless steel.

The oil system is closed, and the oil level can be checked through a liquid indicator on the side of the
cabinet.

The pump’s water connection is mounted using ¾” quick-acting coupling.


The pump’s pressure outlet is mounted with a 3/8” quick-acting coupling
nipple.

The pump pressure can be read in bars (CPA) on an adapted pressure gauge.

Start/stop system
The machine’s start/stop system is controlled by a microprocessor that stops/interrupts the signal from
a reed switch. The reed switch is activated by the flow of a magnetic piston mounted in the pump outlet’s
flow control through the pump.

The start switch has 3 settings:

0 = Machine stopped.

I = Aut. start/stop. Machine stopped with automatic stop function if the spray handle is not activated
after 20 seconds.

Man = Manuel. Machine started in manual position. The machine stops automatically, however, if the
spray handle is not activated after 5 minutes.
Use the manual position if the machine is set to suction without water inlet pressure.

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Construction B
Electrical system
The electrical system is located in electrical casing placed on the motor/pump unit.
All automatic functions are controlled by a microprocessor built into a circuit board.

Equipment
The machine’s standard equipment consists of:
Ergo 3000 spray handle.
10 mtr. Double wire high-pressure hose.
Tornado nozzle.
¾” quick coupling nipple.

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Function C
Pump Function
The illustration below shows a cross-section of the Poseidon pump.

The pump’s job is to move a given amount of water from the suction side to the high-pressure nozzle.
The volume of water depends on the pistons’ quantity, diameter, impact length, and number of impacts
per minute.

When wobble disc A is turned, the piston is pulled down with the help of retracting spring B, and water
is sucked through suction valve C.

When the piston rises again, the suction valve closes, and pressure valve D opens.
From here, water is propelled towards the pump’s bypass valve.

Because of the high-pressure nozzle’s small opening, considerable force is needed to move the pistons
forward.

In order to reduce lost friction, the force of the motor is transferred to the pistons via the wobble disc’s
oil-soaked E roller bearings.

The pistons are composed of a stainless steel portion, which is controlled by the cylinder and sealed
with oil sleeve F. The upper portion of the piston is ceramic, the seal on the water side consists of a gasket
system.

At the top is textile sleeve G, which seals out high-pressure. A smaller leakage current passes down
to low-pressure sleeve H, and between these two sleeves, the lubrication is drained back to the suction
side through a small channel.

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Function C
Bypass Valve Function

The bypass valve has 4 functions:


1. Protect the machine against excess pressure.
2. Relieve the pressure in bypass.
3. Fast conversion to high-pressure.
4. Ensure 0 pressure when the machine is stopped.

Operation:

The water from the pump is led into chamber A of the bypass valve.
From there, the water passes through hole B in piston C and out of the machine.
This leads to a pressure imbalance in piston C, which keeps valve disc D closed to valve seat E.

Bypass:

When water consumption stops (the spray handle is released), pressure increases briefly until safety valve F
opens upon reaching the pressure setting, which should be adjusted to 25-30 bars over working pressure. This
causes the pressure drop in piston C to disappear, and valve disc D moves from valve seat E. The machine is
now running in bypass.

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Function C
P O S E ID O N S P R A Y

D
F
E
A

B
B

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Function C

P O S E ID O N B Y - P A S S

D
F

E
C
A

B B

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Function C
Flow Control

Flow control consists of:

1. Casing
2. Piston w/ magnet
3. Spring
4. Reed switch

Operation:

A drop in pressure in the piston pushes the piston forward, causing the magnet to activate the reed switch.
A drop in pressure on the piston’s end face causes the piston to remain in this position.

Bypass:

When water is not being consumed, the drop in pressure in the piston stops, and the piston is pushed back
by the spring, deactivating the reed switch.
The pressure is balanced out through the hole in the piston, and the force of the spring holds the piston in a
neutral position.

5 V O L T

S P R A Y .

0 V O L T

B Y - P A S S .

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Function C
PC Board

The circuit board has the following functions:


1. To start the electric motor when starting the machine.
2. To stop the electric motor when operation of the machine is finished.
3. To record and store data concerning the machine’s work situations, operation, and bypass.

The circuit board is protected against excess pressure thanks to a circuit breaker (0.63A- SLOW) placed on
the board.

Start switch positions

0:
The machine is not in operation; there is no power from the Start/Stop switch to print and the contactor’s
magnetic pole.

1:
The machine is set to automatic start/stop operation.

When you activate the spray handle and water is flowing through the machine, the flow sensor’s reed switch
signals the circuit board’s microprocessor, and the machine runs uninterrupted.

When you release the spray handle, and water flow through the machine stops, the signal to the PC board’s
microprocessor is interrupted. After a 20-second delay, power to the contactor’s magnetic pole is cut off, and
the electric motor stops.

Man:

The machine is set to manual operation.

The flow sensor is monitored via the reed switch but is not active.

The electric motor runs uninterrupted regardless of whether or not the reed switch registers water flow.

When you release the spray handle and the water flow through the machine stops, the power to the Start/Stop
switch and to the contactor’s magnetic pole is cut off after 5 minutes.
The machine must then be restarted using the Start/Stop switch.

Service functions:

1. Identification of machine and software type.


2. Read-out of number of starts.
3. Read-out in hours/minutes of operating time under flow.
4. Read-out in hours/minutes of bypass time.

These read-outs are made with ALTO SB Datalogger .

A description of SB Datalogger will be added later.

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Trouble-shooting D
Operating Requirements

To ensure error-free operation, the following requirements must be met:


1. Machine and equipment must be free of air and without leaks.

2. Water temperature must not exceed 85°C when inlet pressure on water supply.

3. In suction mode, water temperature must be significantly lower, depending on the suction
height. Make sure the pump does not cavitate (water boils under vacuum).

4. Water quality must be free of impurities > 50 µ.

5. Water supply must be sufficient at all times.

6. Ambient temperature must not exceed 40°C.

7. Supply voltage must not vary by more than 6% of the given value.
Temperature sensor in motor
Electrical connections + plug

Suction cup on bypass valve


Pump pressure + h-p nozzle
Piston for bypass valve

O-ring in cylinder head


Pressure valve + seat

Oil sleeve + oil hoses


Suction valve + seat

Bypass valve + disc

Water temperature
Print + reed switch

Pressure sleeve
Circuit breakers
Contactor + coil

Leaks in hoses

Suction sleeve
Suction height
Water supply
Safety valve

Flow control
Start switch

Air in pump
Water filter

Poss. cause/ Check


Symptom:
Motor doesn't start X X X X X X X
Motor doesn't stop X
Motor stops X X X X X X
Max. pressure too high X
Max. pressure too low X X X X X X X X X X X X
Max. pressure irreg. in suction X X X X X X X X
Max. pressure 50-70 bars X X X
Max. pressure pulsating X X X
Bypass pressure too high X X X
Oil consumption too high X
Pump run only bypass X X
Bypass valve "thumps" X X X
Uneven pressure during operation X X
Pump doesn't go into bypass X X

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Service/Repair E
Safety valve

The safety valve’s factory setting for opening pressure = working pressure + 25 to +30 bars.
Upon each service inspection the setting must be tested and, if necessary, adjusted.
When mounting, affix ball and pressure plate to the spring with lubrication.
The seat is screwed on using a 10mm socket wrench (no gasket required).
Before testing with a pressure gauge, make sure that two threads are visible behind the locknut.

Warning: Before starting the pump, check that the test manometer valve is open. Close the valve slowly;
pressure must never exceed 250 bars.

Pressure side
10mm special wrench
no.: 1206754

6mm Allen wrench

Suction side

M a x . 2 5 0 b a r.
M a n

o
1

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Service/Repair E
Valve cylinder head 1

Removal and mounting is done manually.


Lubricate the large O ring with grease.

Lubrication duct
Pressure valve seat

y
ne
en
K
Suction valve seat

Nylon ring

Textile sleeve (hard)

Back-up ring

Rubber sleeve (soft)

Remove the suction valve seat using impact piercer no. 1216506.
Press out the pressure valve using a 2 mm piercer.
Check valve seats.
Mount again with fingers.

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Service/Repair E
Valve cylinder head 2

Lock/back-up ring
O-ring
Rubber sleeve secondary

Thrust collar

Back-up ring

Textile sleeve

Expansion/back-up ring

K e
nn
ey

Suction valve Pressure valve

O-ring

When mounting textile sleeves, use tool no.: 1220090.


It helps to place the sleeves in a water bath 3-4 hours before mounting.
Remember to blow through the lubrication ducts with compressed air.

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Service/Repair E
Cylinder block 1

Oil filling
Plate

O-ring
Torque: 37 Nm

Oil sleeve

Back-up ring

Oil draining

Always replace secondary sleeves when


replacing pressure sleeves.
Check for free passage in the thrust
collar’s drainage holes.
Drain the oil by loosening the plug at the bottom of the cylinder
block.
Loosen the 8 nuts evenly in consideration of the pressure from
the piston springs.
Use special head no. 1206762.
Mount new O rings on stay bolts using tool no. 1206812.

When changing the oil, loosen the hose connection above


the cylinder block.
Oil (0.5 litres) is poured into the threaded hole.

Testing has shown that the pump does not consume oil
during normal operation.
In other words, under normal circumstances you do not
need to refill oil in the pump.
Nevertheless, the oil level and quality must be checked
regularly through the liquid indicator.

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Service/Repair E
Cylinder block 2

Carefully lift the oil


sleeves out with a
suitable screwdriver and
dispose of them.
Be careful not to scrape
the surface.

Before inserting the new


sleeves, it is a good idea
to moisten the sleeves
with soapy water.
Insert new oil sleeves
using piercer no.
1220429.

Gently tap or press in.

Oil sleeve Low-pressure High-pressure


Inspect the piston for
wear on the contact
surface and in the
area for oil sleeves.
Examine the ceramic
for cracks, and wipe
Contact surface Stainless steel Ceramic clean any deposits.

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Service/Repair E
Motor / wobble disc 1

The motor consists of a stator with windings, a rotor with an axel that is held in place with a bearing in
the N-bearing cover and the wobble disc’s innermost needle bearing in the D-bearing cover.
Ventilator 4 is pressed onto the rotor over locking bush 5 and is mounted with two screws.
The wobble disc’s pressure plate 23 is held in place with peg 22. Plate 21 ensures that needle bearing
24 is held apart from oil sleeve X.

s ta to r ro to r
4 N D

23

2 2
x
2 1
2 7

Remove locking ring 27.


The wobble disc is easily removed with
wheel dresser no. 1205715 and special
leg no.1206150/1206168.
Remember to remove parallel key 17 before
removing D-bearing cover.
Check bearing surfaces for wear.
If in doubt, replace set 28 completely.

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Service/Repair E
Motor / wobble disc 2
When mounting complete D bearing cover,
protect the oil sleeve using tool no. 1206598,
and place it on the axel before mounting

24
25
26 27
30
31
32

When mounting the wobble disc, lubricate the bearings with oil. The large roller bearings 25 and 31 are
identical. Remember to place locking ring 27 on the axel.

No. 26 No. 32

Inspect the bearing surfaces for wear. As long as there is only regular wear without holes or ridges, as in the
pictures above, the wobble disc can be used again.

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Adjustment/Test F
Adjustment of reed switch

Place the reed switch in the plastic case with the screw loose enough so that the switch can still be moved
back and forth.
Place the reed switch as far forward in the direction of the water outlet as possible.
Start the machine on setting 1, without a water connection.
After approx. 20 seconds, the machine stops, and you can then adjust the reed switch.
Slowly push the reed switch back until the machine starts.
Next pull the reed switch approx. 3 mm away from the machine, and tighten the screw in the plastic
casing.
Finally, test the start/stop function with a water connection to the machine.

This adjustment can also be made with an ohmmeter. In that case, remember to disconnect the machine
from the power source.

B Y - P A S S .

3 - 4 m m .

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Adjustment/Test F
Torque

Poseidon_GB01 2
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Poseidon_GB01

1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

0
1
A 1
2

b l S 1
L 3 X 1 0 V
2 2 a
b r X 5 A 1 S te u e r p la tin e C o n tro l P C B
L 2 X 2 2 3 0 V
P ro g ra m m
s w B 2 S tro e m u n g s w a e c h te r F lo w s e n s o r
L 1 X 3 4 0 0 V
1 1 a B 3 T h e r m o s c h a lte r M o to r T h e r m a l s w itc h m o to r
F lo w S u c k in g

Wiring Diagrams
P E X 4 S c h ü tz
X 7 X 6 K 1 S c h u e tz C o n ta c to r
1 2 1 2 3 4

M 1 M o to r 3 p h M o to r 3 p h
B 2 4
S 1 S 1 D r e h s c h a lte r R o ta ry s w itc h
Q
4 a X m a /b M o to rs te c k e r M o to r c o n n e c to r
1 3 5
X 1 0 S a m m e lk le m m e C o n c e n tr a tio n te r m in a l
A 1
K 1
s w s c h w a rz b la c k
A 2
2 4 6 b r b ra u n b ro w n
b l b la u b lu e

X 1 0

X m a
X m b
1 2 3 6 5 4 7 9
(1 4 )
U 1 V 1 W 1

M 1
M
3 ~
U 2 V 2 W 2 B 3

Ä n d e ru n g D a tu m N a m e D a tu m N a m e B e z . Z e ic h n .- N r .:
g e z . 2 7 .0 9 .0 1 P o e s c h l R
3 p h S te rn 7 1 1 8 6
B l.
1
P r o je k tb e z .
g e p .
P o s e id o n v o n 1
G
1

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Poseidon_GB01

1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0
0
1 A 1
2

b l
S 1
L 3 X 1 0 V
2 2 a
b r X 2 2 3 0 V X 5
L 2
P ro g ra m m
s w
L 1 X 3 4 0 0 V
1 1 a
F lo w S u c k in g
P E X 4 S c h ü tz X 7 X 6
1 2 1 2 3 4
1 3 5
K 1

Wiring Diagrams
4
2 4 6 B 2
Q
S 1
4 a

1 4
K 1
1 3

1 2 3 4 5 6 7 8
R 1
S 2
2 5 A 1 S te u e r p la tin e C o n tro l P C B
1 a 2 a 3 a 4 a 5 a 6 a 7 a 8 a

B 2 S tro e m u n g s w a e c h te r F lo w s e n s o r
2 6
B 3 T h e r m o s c h a lte r M o to r T h e r m a l s w itc h m o to r

K 1 S c h u e tz C o n ta c to r
K 1 A 1
M 1 M o to r 3 p h M o to r 3 p h
A 2
R 1 W id e r s ta n d R e s is to r
X m a
X m b S 1 D r e h s c h a lte r R o ta ry s w itc h
1 2 3 6 5 4 S 2 S te r n - D r e ie c k - S c h a lte r S ta r - tr ia n g le s w itc h
7 9
(1 4 )
X m a /b M o to rs te c k e r M o to r c o n n e c to r
U 1 V 1 W 1 X 1 0 S a m m e lk le m m e C o n c e n tr a tio n te r m in a l

M 1 s w s c h w a rz b la c k
M
b r b ra u n b ro w n
3 ~ b l b la u b lu e
U 2 V 2 W 2 B 3
S 2 Z e ic h n u n g S c h a lte r s te llu n g S te rn

S 2 D r a w in g s w itc h p o s itio n s ta r

Ä n d e ru n g D a tu m N a m e D a tu m N a m e

P o e s c h l R
B e z .
3 p h u m s c h a ltb a r Z e ic h n .- N r .:
7 1 1 9 9 B l.
1
g e z . 1 6 .1 1 .0 1
P r o je k tb e z .
g e p . P o s e id o n v o n 1
G
2

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Poseidon_GB01

1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

0
1
2 A 1
S 1 X 1 0 V A 1 S te u e r p la tin e C o n tro l P C B
N
2 2 a
X 5 B 2 S tro e m u n g s w a e c h te r F lo w s e n s o r
P ro g ra m m B 3 T h e r m o s c h a lte r M o to r T h e r m a l s w itc h m o to r

P H X 2 2 3 0 V
1 1 a C 1 B e tr ie b s k o n d e n s a to r o p e r a tin g c a p a c ito r
X 3 4 0 0 V

Wiring Diagrams
K 1 S c h u e tz C o n ta c to r
P E
X 4 S c h ü tz F lo w S u c k in g
X 7 X 6 M 1 M o to r 1 p h M o to r 1 p h
1 2 1 2 3 4

S 1 D r e h s c h a lte r R o ta ry s w itc h

B 2 S 1 4
X m a /b M o to rs te c k e r M o to r c o n n e c to r
Q X 1 0 S a m m e lk le m m e C o n c e n tr a tio n te r m in a l
1 3 5 A 1 4 a
K 1 X 1 1 /1 2 R e ih e n k le m m e T e r m in a l S tr ip

2 4 6 A 2

X 1 1

C 1
X 1 0 X 1 2

X m a
X m b 7 9
1 5 3 6 4 2
(1 4 )
U 1 Z 1

M 1
M
1 ~
U 2 Z 2 B 3

Ä n d e ru n g D a tu m N a m e D a tu m N a m e B e z . Z e ic h n .- N r .:
B l.
1 p h S ta n d a rd 7 1 2 0 5 1
g e z . 2 8 .0 1 .0 2 P o e s c h l R

P r o je k tb e z .
g e p . P o s e id o n v o n 1
G
3

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Spare Parts Proposal H

1
0 7
0 0
6 3
1 8 0 2 5 2 9

6 1 0 0 6 6 6
9 9
9 8 6 3 0 1 1 6 6

2 6 0 2 2 7 4
9 7 = 1 1 1 9 5 7 1
9 8 = 1 1 1 9 8 2 0
9 9 = 1 1 1 9 5 7 0
9 9
9 8

6 1 0 0 6 1 0

9 7
9 9

6 3 0 1 3 3 5

1 0 7 1 2 0 7 0 0
5
1 9
1 9
1 1
0
0 8
0 0
6 3

9
0 7
0 0
6 3

9 7
9 9
9 7
9 9

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Spare Parts Proposal H

1 0 1 1 1 9 4 1 0

3 0 0 1 1 7 9
3 6 0 1 2 6 2

0
5 8 6 4 4 1
1 8
1 1

5
9 2
0 0
6 1
6 1 0 1 0 4 2
3 0 0 1 7 1 6
6 1 0 1 0 6 1
1 6 0 2 9 4 5

6 1 0 0 9 4 1

1 1 1 8 5 1 2

1 0 1 1 1 9 4 1 1

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Spare Parts Proposal H

9 9

6 1 0 0 6 1 1

3 2 0 0 6 2 3

0
7 5 6 1 0 1 7 4 9
0 1
6 1
9 9 9 9
9 8

3 2 0 0 6 5 6

1 8 0 2 5 1 1

3 2 0 0 6 1 5

3 2 0 0 6 1 5

9 8 = 1 1 1 9 8 2 0
9 9 = 1 1 1 9 5 7 0
1 0 7 1 2 0 7 0 4
3 2 0 0 6 6 4

Poseidon_GB01 3
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