Nilfisk-ALTO NEPTUNE 5 FA User manual

Service Manual
NEPTUNE 5 FA
NEPTUNE 5 FA_EN_Ver.2.0_25/11

NEPTUNE 5 FA_EN_Ver.2.0_25/11 2
This service manual contains detailed description of the main repair work on the hot HPW
NEPTUNE 5.
Repair work requires a suitable testing workplace with the necessary water and power supply.
If operating errors are evident, refer the customer to the operating instructions.
A fault in the cleaner can have several causes as described in the section on troubleshooting.
Refer to the illustrated spare parts lists during repairs. They show the assembly position and the
sequence in which the individual components should be assembled.
See ”Service Technical Information” (STI) sheets. They include information on technical
modifications that have been made after this repair manual was printed.
”Service Technical Information” sheets are also valid as a supplement to the spare parts list until
publication of a new edition.
Repair manuals and ” Service Technical Information” sheets should be available at the site
where repairs are carried out.
It is not permitted to give them to third parties.
Use original Nilfisk-ALTO spare parts only.
Preface

A.
B.
C.
D.
E.
F.
G.
H.
I. Special tools /
Spare parts
Wiring diagrams 54-61
Adjustment / Test 49 -53
Service / Repair 36 -48
Troubleshooting 32-35
Function 25-31
Construction 19 -24
Technical data 5-18
Safety instructions 4

A
Safety instructions
4
NEPTUNE 5 FA_EN_Ver.2.0_25/11
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 operating instructions
and keep them 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
authorized 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
5
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
5-50FA EU
400V/3 ~50Hz 16A
5-50FAX EU
400V/3 ~50Hz 16A
Item no.
Tol. 107146650 107146651
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Pump-Data
Max. inlet pressure (bar) 10,0 10,0
Max. Inlet temperature (°C) 40,0 40,0
Pressure at pump head 0 175 10 10 180 10 10
Pressure @ Cylinder Head (bar) 0 180 10 10 185 10 10
Pressure @ Outlet (bar) 0 163 9 9 166 9 9
Pressure @ Gun (bar) 0 140 8 8 144 8 8
Pressure cut off
@ Cylinder Head (bar) 200 5 5 205 5 5
Pressure Pmax safety valve @
Cylinder Head (bar) 250,0 5,0 5,0 250,0 5,0 5,0
Flow. Qiec (l/min) 2,5% 13,6 0,3 0,3 13,6 0,3 0,3
Flow. Qmax (l/min) 5% 14,6 0,7 0,7 14,6 0,7 0,7
Flow. Qmin, steam (l/min) 3% 6,3 0,2 0,2 6,3 0,2 0,2
Type NA5 NA5
Piston type Cermic Cermic
Piston diameter (mm) 20,0 20,0
Stroke / Wobble disc angle 10,2 10,2
Pump oil type
Oil BP Energol
GR-XP220
Oil BP Energol
GR-XP220
Oil volume (l) 0,8 0,8
Electrical
Power supply 400V/3~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 12,2 1,0 3,0 12,3 1,0 3,0
Current consump. - cold (A) 12,4 1,0 3,0 12,5 1,0 3,0
Power Consumption - hot (kW) 6,0 0,5 0,5 6,1 0,5 0,5
Fuse size (A) 16,0 16,0
Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G1,5 x 6m
Plug type CEE 3P+N+G / 16A CEE 3P+N+G / 16A
Control PCB 24 volt PCB 24 volt
Contactor 100-C16KJ10 24 100-C16KJ10 24
Electrical diagram 106427171 106427171
Eletrical test data
Highvoltage (HV) test (V) 1000 Vac 1000 Vac
HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc
Cord-resistance (Ohm) 0,2 0,2
Motor-Data
Motortype 3~ Induction 3~ Induction
Rotational speed (min-1) 1450 1450
Insulation Class F Class F
Protection Class IP 54 IP 54
Nominal power [kW] 5,5 3,0 3,0 5,5 3,0 3,0
Cos j 0,7 0,7

B
Technical data
6
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
5-50FA EU
400V/3 ~50Hz 16A
5-50FAX EU
400V/3 ~50Hz 16A
Item no.
Tol. 107146650 107146651
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Heating Unit
Boilerpower_input (kW) 78,0 78,0
Temperature t max, @ inlet 12°C 87,7 0,0 3,0 87,7 0,0 3,0
Delta temp. variance at 50 °C
set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0
Boiler on time at 50 °C set point,
@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0
Steam temp. t II @ outlet and v.
Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0
Pressure P2 @ outlet with
standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0
Fuel pump type Diesel Diesel
Oil pressure ( bar ) 10,0 0,5 0,0 10,0 0,5 0,0
Nozzle size, oil 1,75 60°H 1,75 60°H
CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0
Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5
Soot picture 0-1 0-1
Exhaust outlet temperature (°C) 175,0 10,0 10,0 175,0 10,0 10,0
Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0
Fuel consump. @ dT=45 deg(kg/h) 4,0 4,0
Fuel consumption (kg/h)
@ 12°C inlet 6,7 6,7
Water volume in coil (l) 4,8 4,8
Fuel tank (l) 17,0
Others
Gun ST ERGO 2000 ST ERGO 2000
Lance TORNADO PLUS TORNADO PLUS
Hose DN 8x10m 3/8" DN 8x20m
High Pressure Nozzle NT 0500 NT 0500
Noise level 1m Lpa( dBA) 76,6 1,5 1,5 76,6 1,5 1,5
Noisepower LWA (dB) A 93,0 1,5 1,5 93,0 1,5 1,5
Impact force N 44,0 45,0
Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5
Protection Class IP X5 IP X5
Max detergent flow
from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0
Max detergent flow
from full internal tank (L/min) 0,5 0,2 0,2 0,5 0,2 0,2

B
Technical data
7
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
SB FA EU
400V/3 ~50Hz 10A
5-61FA EU
400V/3 ~50 16A
Item no.
Tol. 107146652 107146653
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Pump-Data
Max. inlet pressure (bar) 10,0 10,0
Max. Inlet temperature (°C) 40,0 40,0
Pressure at pump head 0 75 4 4 190 10 10
Pressure @ Cylinder Head (bar) 0 80 4 4 195 11 11
Pressure @ Outlet (bar) 0 72 4 4 193 11 11
Pressure @ Gun (bar) 0 67 4 4 168 9 9
Pressure cut off
@ Cylinder Head (bar) 100 5 5 215 5 5
Pressure Pmax safety valve @
Cylinder Head (bar) 120,0 5,0 5,0 250,0 5,0 5,0
Flow. Qiec (l/min) 2,5% 12,1 0,3 0,3 15,8 0,4 0,4
Flow. Qmax (l/min) 5% 13,1 0,7 0,7 16,9 0,8 0,8
Flow. Qmin, steam (l/min) 3% 5,6 0,2 0,2 9,2 0,3 0,3
Type NA5 NA5
Piston type Cermic Cermic
Piston diameter (mm) 20,0 20,0
Stroke / Wobble disc angle 9,2 12,0
Pump oil type
Oil BP Energol
GR-XP220
Oil BP Energol
GR-XP220
Oil volume (l) 0,8 0,8
Electrical
Power supply 400V/3~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 8,0 1,0 3,0 15,4 1,0 3,0
Current consump. - cold (A) 8,2 1,0 3,0 16,0 1,0 3,0
Power Consumption - hot (kW) 4,1 0,5 0,5 7,6 0,5 0,5
Fuse size (A) 16,0 16,0
Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G1,5 x 6m
Plug type CEE 3P+N+G / 16A CEE 3P+N+G / 16A
Control PCB 24 volt PCB 24 volt
Contactor 100-C12KJ10 5,5kW 100-C16KJ10 24
Electrical diagram 106427171 + 71371 106427171
Eletrical test data
Highvoltage (HV) test (V) 1000 Vac 1000 Vac
HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc
Cord-resistance (Ohm) 0,2 0,2
Motor-Data
Motortype 3~ Induction 3~ Induction
Rotational speed (min-1) 1450 1450
Insulation Class F Class F
Protection Class IP 54 IP 54
Nominal power [kW] 3,0 3,0 3,0 6,7 3,0 3,0
Cos j 0,8 0,7

B
Technical data
8
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
SB FA EU
400V/3 ~50Hz 10A
5-61FA EU
400V/3 ~50 16A
Item no.
Tol. 107146652 107146653
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Heating Unit
Boilerpower_input (kW) 67,0 85,0
Temperature t max, @ inlet 12°C 85,2 0,0 3,0 83,0 0,0 3,0
Delta temp. variance at 50 °C
set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0
Boiler on time at 50 °C set point,
@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0
Steam temp. t II @ outlet and v.
Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0
Pressure P2 @ outlet with
standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0
Fuel pump type Diesel Diesel
Oil pressure ( bar ) 12,0 0,5 0,0 12,0 0,5 0,0
Nozzle size, oil 1,35 60°H 1,75 60°H
CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0
Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5
Soot picture 0-1 0-1
Exhaust outlet temperature (°C) 160,0 10,0 10,0 175,0 10,0 10,0
Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0
Fuel consump. @ dT=45 deg(kg/h) 3,5 0,0 0,1 4,6
Fuel consumption (kg/h)
@ 12°C inlet 5,7 0,0 0,0 7,3
Water volume in coil (l) 4,8 4,8
Fuel tank (l) 17,0 17,0
Others
Gun ST ERGO 2000 ST ERGO 2000
Lance TORNADO PLUS TORNADO PLUS
Hose DN 8x10m Quick 3/8" DN 8x10m Quick 3/8"
High Pressure Nozzle NT 0700 NT 0550
Noise level 1m Lpa( dBA) 76,4 1,5 1,5 78,2 1,5 1,5
Noisepower LWA (dB) A 92,0 1,5 1,5 96,0 1,5 1,5
Impact force N 26,0 53,0
Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5
Protection Class IP X5 IP X5
Max detergent flow
from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0
Max detergent flow
from full internal tank (L/min) 0,5 0,2 0,2 0,6 0,2 0,2

B
Technical data
9
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
5-61FAX EU
400V/3 ~50 16A
5-61FA NO
400V/230/3 ~
50Hz 25/16A
Item no.
Tol. 107146654 107146655
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Pump-Data
Max. inlet pressure (bar) 10,0 10,0
Max. Inlet temperature (°C) 40,0 40,0
Pressure at pump head 0 195 11 11 190 10 10
Pressure @ Cylinder Head (bar) 0 200 11 11 195 11 11
Pressure @ Outlet (bar) 0 197 11 11 193 11 11
Pressure @ Gun (bar) 0 170 9 9 168 9 9
Pressure cut off
@ Cylinder Head (bar) 220 5 5 215 5 5
Pressure Pmax safety valve @
Cylinder Head (bar) 250,0 5,0 5,0 250,0 5,0 5,0
Flow. Qiec (l/min) 2,5% 15,8 0,4 0,4 15,8 0,4 0,4
Flow. Qmax (l/min) 5% 16,9 0,8 0,8 16,9 0,8 0,8
Flow. Qmin, steam (l/min) 3% 9,3 0,3 0,3 9,2 0,3 0,3
Type NA5 NA5
Piston type Cermic Cermic
Piston diameter (mm) 20,0 20,0
Stroke / Wobble disc angle 12,0 12,0
Pump oil type
Oil BP Energol
GR-XP220
Oil BP Energol
GR-XP220
Oil volume (l) 0,8 0,8
Electrical
Power supply 400V/3~/50Hz 400/230V/3~/50Hz
Current consump. - hot (A) 15,8 1,0 3,0 15,6 / 25 1,0 3,0
Current consump. - cold (A) 16,0 1,0 3,0 15,8 / 25 1,0 3,0
Power Consumption - hot (kW) 7,8 0,5 0,5 7,6 / 7,4 0,5 0,5
Fuse size (A) 16,0 28 / 16
Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G2,5x6,0
Plug type CEE 3P+N+G / 16A -
Control PCB 24 volt PCB 24 volt
Contactor 100-C16KJ10 24 100-C23KJ10
Electrical diagram 106427171 106427177
Eletrical test data
Highvoltage (HV) test (V) 1000 Vac 1000 Vac
HV-Resistance (MΩ) ≥1MΩ/ 500Vdc ≥1MΩ/ 500Vdc
Cord-resistance (Ohm) 0,2 0,2
Motor-Data
Motortype 3~ Induction 3~ Induction
Rotational speed (min-1) 1450 1450
Insulation Class F Class F
Protection Class IP 54 IP 54
Nominal power [kW] 6,7 3,0 3,0 6,7 3,0 3,0
Cos j 0,7 0,8

B
Technical data
10
NEPTUNE 5 FA_EN_Ver.2.0_25/11
NEPTUNE 5 FA
Description
5-61FAX EU
400V/3 ~50 16A
5-61FA NO
400V/230/3 ~
50Hz 25/16A
Item no.
Tol. 107146654 107146655
Technical data Test result Tol.+ Tol.- Test result Tol.+ Tol.-
Heating Unit
Boilerpower_input (kW) 85,0 85,0
Temperature t max, @ inlet 12°C 83,0 0,0 3,0 83,0 0,0 3,0
Delta temp. variance at 50 °C
set point, at @ gun (°C) 30,0 0,0 3,0 30,0 0,0 3,0
Boiler on time at 50 °C set point,
@ inlet 12° (sec) 30,0 5,0 5,0 30,0 5,0 5,0
Steam temp. t II @ outlet and v.
Steam nozzle(°C) 140,0 10,0 30,0 140,0 10,0 30,0
Pressure P2 @ outlet with
standard nozzle (bar) 27,0 5,0 5,0 27,0 5,0 5,0
Fuel pump type Diesel Diesel
Oil pressure ( bar ) 12,0 0,5 0,0 12,0 0,5 0,0
Nozzle size, oil 1,75 60°H 1,75 60°H
CO2 content min ( % ) 10,5 0,5 0,0 10,5 0,5 0,0
Efficiency burner ( % ) 92,0 1,5 0,5 92,0 1,5 0,5
Soot picture 0-1 0-1
Exhaust outlet temperature (°C) 175,0 10,0 10,0 175,0 10,0 10,0
Exhaust temperature, cut off (°C) 270,0 0,0 12,0 270,0 0,0 12,0
Fuel consump. @ dT=45 deg(kg/h) 4,6 4,6
Fuel consumption (kg/h) 7,3 7,3
Water volume in coil (l) 4,8 4,8
Fuel tank (l) 17,0 17,0
Others
Gun ST ERGO 2000 ST ERGO 2000
Lance TORNADO PLUS TORNADO PLUS
Hose DN 8x20m 3/8" DN 8x20m 3/8"
High Pressure Nozzle NT 0550 NT 0550
Noise level 1m Lpa( dBA) 78,2 1,5 1,5 78,2 1,5 1,5
Noisepower LWA (dB) A 96,0 1,5 1,5 96,0 1,5 1,5
Impact force N 54,0 53,0
Vibration ISO 5349 ( m/s² ) ≤2,5 ≤2,5
Protection Class IP X5 IP X5
Max detergent flow
from full internal tank (%) 4,0 1,0 1,0 4,0 1,0 1,0
Max detergent flow
from full internal tank (L/min) 0,6 0,2 0,2 0,6 0,2 0,2