Nilfisk-ALTO NEPTUNE PE User manual

Service Manual
NEPTUNE PE/DE
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd

A.
B.
C.
D.
E.
F.
G.
H. Wiring diagrams 72-92
Adjustment / Test 63-71
Service / Repair 42-62
Troubleshooting 38-41
Function 18-37
Construction 10-17
Technical data 6- 9
Safety instructions 5
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Index
3
NEPTUNE PE-DE_en_Ver.1.0_October 2010
A.Safety instructions ...................................................5
B.Technical data...........................................................6
C.Constrution
-Overview Unit: ..........................................................13
D.Function
-Electrical....................................................................18
-Funktion PCB............................................................24
-Pumps.......................................................................28
-By-pass valves & Unloader…………………………....31
-Flow Switch…………………………………………… ..35
-Heat Exchanger.........................................................36
E. Troubleshooting
-Table .........................................................................38
F. Service / Repair
-NA5 Pump.................................................................42
-C3 Pump ...................................................................48
-NP5 Pump.................................................................54
-Heat Exchanger ........................................................59
-Electrodes .................................................................61
-Maintenance………… ...............................................62
G.Adjustment / Test
-NA5 ...........................................................................63
-C3..............................................................................66
-NP5 ...........................................................................67
-Heat Exchanger.........................................................69
H.Wiring diagrams
- .................................................................................72
Jetwash Direct ltd

NEPTUNE PE-DE_en_Ver.1.0_October 2010
4
This service manual contains detailed description of the main repair work on the Hot
Water High Pressure Washer, NEPTUNE PE—DE.
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 trouble-
shooting.
Refer to the illustrated spare parts lists during repairs. They show the assembly posi-
tion and the sequence in which the individual components should be assembled.
Repair manuals and TSB (Technical Service Bulletin) 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
Jetwash Direct ltd

A
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Safety instructions
5
For your own safety
Before using the cleaner, al-
ways read the operating
instructions and keep them
readily available.
The high-pressure cleaner
should only be used by author-
ized persons who have been
instructed in its use.
Although extremely easy to
operate, children should not
be allowed to use the cleaner.
Repair work should be carried
out by persons instructed and
trained in repairing this product.
Jetwash Direct ltd

B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010 6
Motor Manufacturerand type Honda GX 340 Honda GX 390
Power HK/RPM 9,5/3600 11,0/3600
Fuel type Petrol Petrol
CCM Cm3 337 389
Fuel tank capacity Liter 6,1 6,1
Motor RPM, adjusted RPM 3550 3400
Pulley size mm SPZ 55,4/1 SPZ 55,4/1
Motor oil type SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,1 1,1
Type NA5 NA5
Pump pressure bar 188 198
Machine outlet pressure bar 167 170
Water Quantity, high pressure l/min 12 13,5
Water Quantity, low pressure l/min 13,5 15
Suctioncapacity(feeded) meter 3 3
Pump inlet temperature °C 35-40 35-40
Fuel pressure bar 12 10
Fuel consumption dt = 45 °C kg/h 3,9 3,9
CO2content (min.) % 10,5 10,5
Soot rating 0 0
Efficiency % 92 92
Onboard fuel tank Litre 57 57
Heater rating kW 68 81
Delta T@ working pressure ºC 75 81
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlleySize SPZ63/1 SPZ60/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 970
Width mm 780 780
Height mm 1000 1000
Weight kg 208 208
Sound power level CE, Lwa Db 105 105
High-pressure hose DN8 m 15 15
HP nozzle 0400 0450
NEPTUNE 5-46PE NEPTUNE 5-54PE
Miscella
neous Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchangerGenerator
Jetwash Direct ltd

B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010 7
Motor Manufacturerand type Honda GX 390 Honda GX 630
Power HK/RPM 11,0/3600 20,8/3600
Fuel type Petrol Petrol
CCM Cm3 389 670
Fuel tank capacity Liter 6,1 20 (External tank)
Motor RPM, adjusted RPM 3550 3340
Pulley size mm SPZ 55,4/1 SPZ 80/4
Motor oil type SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,1 1,9
Type C3 NP5
Pump pressure bar 202 210
Machine outlet pressure bar 192 195
Water Quantity, high pressure l/min 16 20
Water Quantity, low pressure l/min 18 21,5
Suctioncapacity(feeded) meter 3 5
Pump inlet temperature °C 35-40 35-40
Fuel pressure bar 11 12
Fuel consumption dt = 45°Ckg/h 4,6 5,75
CO2content (min.) % 10,5 10,5
Soot rating 0 0-1
Efficiency % 92 92
Onboard fuel tank Litre 57 57
Heater rating kW 87 111
Delta T@ working pressure ºC 70 70
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlleySize SPZ63/1 SPZ60/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 1130
Width mm 780 910
Height mm 1000 1050
Weight kg 210 260
Sound power level CE,Lwa Db 105 106
High-pressure hose DN8 m 15 15
HP nozzle 0500 0650
NEPTUNE 7-61PE NEPTUNE 5-85PE
Miscella
neous Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchangerGenerator
Jetwash Direct ltd

B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010 8
Motor Manufacturer and type Yanmar Ruggerini
Power HK/RPM 10/3600 16/3500
Fuel type Diesel Diesel
CCM Cm3 406 -
Fuel tank capacity Liter 5,5 20 (External tank)
Motor RPM, adjusted RPM 3530 3500
Pulleysize mm SPZ80/3 -
Motor oil type SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,65 1,8
Type NP5 C3
Pump pressure bar 185 185
Machine outlet pressure bar 176 170
Water Quantity, high pressure l/min 13,5 18,7
Water Quantity, low pressure l/min 15 20
Suctioncapacity(feeded) meter 3 5
Pump inlet temperature °C 35-40 35-40
Fuel pressure bar 10 12
Fuel consumption dt = 45°Ckg/h 3,9 4,85
CO2content (min.) % 10,5 10,5
Soot rating 0 0-1
Efficiency % 92 92
Onboard fuel tank Litre 57 57
Heater rating kW 81 111
Delta T@ working pressure ºC 81 76
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlleySize SPZ63/1 SPZ60/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 1130
Width mm 780 910
Height mm 1000 1050
Weight kg 220 315
Sound power level CE, Lwa Db 110 112
High-pressure hose DN8 m 15 15
HP nozzle 0450 0650
NEPTUNE 5-51DE NEPTUNE 7-66DE
Miscella
neous Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchangerGenerator
Jetwash Direct ltd

B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010 9
Motor Manufacturer and type Mitsubishi
Power HK/RPM 16/1630
Fuel type Diesel
CCM Cm3 1318
Fuel tank capacity Liter 20 (External tank)
Motor RPM, adjusted RPM 1600
Pulleysize mm -
Motor oil type SAE 15/40
Motor oil capacity Liter 4,2
Type C3
Pump pressure bar 200
Machine outlet pressure bar 185
Water Quantity, high pressure l/min 19,5
Water Quantity, low pressure l/min 21,5
Suctioncapacity(feeded) meter 5
Pump inlet temperature °C 35-40
Fuel pressure bar 12
Fuel consumption dt = 45°C kg/h 5
CO2content (min.) % 10,5
Soot rating 0-1
Efficiency % 92
Onboard fuel tank Litre 57
Heater rating kW 111
Delta T@ working pressure ºC 76
Type t16W-75
Effect W 1000
RPM @ HP and Boiler RPM 2825
PUlleySize SPZ63/1
Belt dimension Motor/Gen. SPZ 670
Length mm 1130
Width mm 910
Height mm 1050
Weight kg 510
Sound power level CE, Lwa dB 99
High-pressure hose DN10 m 15
HP nozzle 0640
NEPTUNE 7-72DE
Miscella
neous Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchangerGenarator
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 10
Overview NEPTUNE 5-46PE and 5-54PE
The NEPTUNE 5-46PE is designed with a
NA5 high pressure pump, a NEPTUNE 5
boiler and a HONDA GX340 motor.
5-54PE has a Honda GX390 motor
Fuel pump access through
the square hole on the right
side of the fuel tank.
Honda motor
230V Generator
NA5 pump
Water regulation—pump
By-Pass valve
Temperature sensor—pump
Oil container w/ oil level switch
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 11
Water outlet
Honda Motor
C3 pump
Water Break tank, OPTIONAL
Water regulator
Anti Scale container, OPTIONAL
Wheels, OPTIONAL
NEPTUNE 7-61PE, front side
NEPTUNE 7-61PE, front side
The NEPTUNE 7-,61PE is designed with
a C3 high pressure pump, a Honda
GX390 motor with 13 HP, control system
same as on the NEPTUNE 3, and a
NEPTUNE 5 boiler
Fuel pump access
through the square
hole in the fuel tank.
Overview NEPTUNE 7-61PE
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 12
Overview NEPTUNE 7-61PE
NEPTUNE 7-61PE, boiler top
IN
OUT
Flame sensorTemperature sensor,
boiler exhaust
Fuel nozzle
Electrodes
Temperature
Sensor
Flow-
switch
Flow-
switch
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 13
NEPTUNE 7-61PE, backside
Overview NEPTUNE 7-61PE
Generator, 230V Top coverCharging relay
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 14
Overview NEPTUNE 5-85PE
The NEPTUNE 5-85PE is designed with a NP5
high pressure pump, a Honda GX630 motor with
20 HP, control system same as on the NEPTUNE
3, and a NEPTUNE 7 boiler
Honda motor
NP5 pump
Temperature
sensor—pump
Oil glass
w/level
switch
Water
inlet Unloa- der
Safety valve.
(This safety valve
is used only on 5-
85PE and 5-
51DE, becasue
the unloader does
not have a safety
valve).
Generator
Battery—12V
Fuel pump access through
the square hole on the right
side of the fuel tank.
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 15
Overview NEPTUNE 5-51DE
The NEPTUNE 5-51DE is designed with
a NP5 high pressure pump, a Yanmar
motor with 10 HP, control system same
as on the NEPTUNE 3, and a NEPTUNE
5 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Battery 12V Generator
230V Yanmar motor
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
Safety valve (only on 5-51DE & 5-85DE)
Unloader & water regulator
NP5 pump
Oil container w/level switch
Thermal dump valve
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 16
Overview NEPTUNE 7-66DE
The NEPTUNE 7-66DE is designed with a
C3 high pressure pump, a Ruggerini motor
with 16 HP, control system same as on the
NEPTUNE 3, and a NEPTUNE 7 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Rugerinni motor
Oil container w/level sensor
Gera box between motor and pump
C3 pump
By-pass valve W/water regulator
Temperature sensor—pump
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

Construction C
NEPTUNE PE-DE_en_Ver.1.0_October 2010 17
Overview NEPTUNE 7-72DE
The NEPTUNE 7-72DE is designed
with a C3 high pressure pump, a Mitsu-
bishi motor with 15 HP, control system
same as on the NEPTUNE 3, and a
NEPTUNE 7 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Temperature
sensor—pump By-pass valve w/ water regu-
lator
C3 pump
Mitsubishi motor
Oil container w/level
sensor
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressu-
re is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd

D
18
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key
moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turn-
ing the motor.
In the ”ON” position the battery is continuously charged by the AC generator (9) through the rectifier
(2).
With the key in “ON” position, the hour counter will count, no matter if the motor is running or not.
Jetwash Direct ltd

D
19
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Circuit board (A2) is monitoring the thermostat on the high pressure pump (15), the motor
oil switch (8) and the oil level switch in the high pressure pump.
If the thermostat on the pump or the motor oil switch is closing (failure) is respectively in-
put 9 and input 8 connected to ground, which causes the LED to light, and at the same
time output 15 is connected to ground.
If the oil level switch closes (failure) input 5 is connected to ground, output 15 is also con-
nected to ground, which pulls the relay (6) and the motor stops. Also the LED for low oil
level will light up.
On this model it is important that the jumper on A2 (2A) is NOT mounted.
Jetwash Direct ltd

D
20
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-51DE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key
moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turn-
ing the motor.
Circuit board (A2) is monitoring the thermostat (E) on the high pressure pump, the motor oil switch
(D) and the oil level switch in the high pressure pump.
If the thermostat (E) on the pump is closing (failure) is input 8 connected to ground, which causes
the LED to light, and at the same time output 15 is connected to
ground.?????????????????????
If the charging generator (I) is not charging, wire (Y) in the regulator (O) is getting 12V and also the
input 7 on A2 is then getting 12V, which makes the charging light lighten.
On this model it is important that the jumper on A2 (2A) is NOT mounted, for the charging system to
work properly.
Jetwash Direct ltd