Nilfisk-ALTO NEPTUNE NEPTUNE 1 User manual

Service Manual
Ver.2.1
NEPTUNE 1
NEPTUNE 2
NEPTUNE 2 SPECIAL

NEPTUNE 1&2_EN_Ver.2.1_45/2014
This service manual contains detailed description of the main repair work on the hot HPW
NEPTUNE 1, NEPTUNE 2 & NEPTUNE 2 Special.
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 un-
til 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.
Wiring diagrams 104-107
Adjustment / Test 99-103
Service / Repair 71-98
Troubleshooting 69-70
Function 55-68
Construction 53-54
Technical data 5-52
Safety instructions 4

A
Safety instructions
4
NEPTUNE 1&2_EN_Ver.2.1_45/2014
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 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
NEPTUNE 1&2_EN_Ver.2.1_45/2014 5
Parent item no: Description:
107145000 NEPTUNE 1-22 EU 230/50/16A
Service data Unit Value
Model
NEPTUNE 1-22
Item no.
107145000
TECHNICAL DATA
PUMP:
Pump pressure water bar 106
Pressure pump outlet @ Qiec bar
Pressure gun outlet @ Qiec bar 83
Retaining pressure* bar -
Flow. Qiec l/min 8,3
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,1
ELECTRIC:
Electric data V/ph/Hz/A/kW 230V/1ph/50HZ/12A/2.8KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421562

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 6
Parent item no: Description:
107145000 NEPTUNE 1-22 EU 230/50/16A
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.4
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0400
Max. Inlet temp. (primed) 40
Max. Inlet temp. (suction) 40
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type FLEXOPOWER PLUS LANCE 990 BEND
Secondary Lance Type None
Hose HP Hose DN6x10 w/swivel, Quick 3/8",155°
Guaranteed sound power 90
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 94
Size - Machine alone L x W x H 607x688x1000

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 7
Parent item no: Description:
107145001 NEPTUNE 1-22 GB 230/50/13A
Service data Unit Value
Model
NEPTUNE 1-22
Item no. 107145001
TECHNICAL DATA
PUMP:
Pump pressure water bar 106
Pressure pump outlet @ Qiec bar
Pressure gun outlet @ Qiec bar 83
Retaining pressure* bar -
Flow. Qiec l/min 8,3
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,1
ELECTRIC:
Electric data V/ph/Hz/A/kW 230/1ph/50Hz/12A/2.8KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421562

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 8
Parent item no: Description:
107145001 NEPTUNE 1-22 GB 230/50/13A
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.4
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0400
Max. Inlet temp. (primed) 40
Max. Inlet temp. (suction) 40
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type FLEXOPOWER PLUS LANCE 990 BEND
Secondary Lance Type None
Hose HP Hose DN6x10 w/swivel, Quick 3/8",155°
Guaranteed sound power 90
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 94
Size - Machine alone L x W x H 607x688x1000

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 9
Parent item no: Description:
107145002 GERNI NEPTUNE 2-16 240/1/50/10
Service data Unit Value
Model
GERNI NEPTUNE 2-16
Item no. 107145002
TECHNICAL DATA
PUMP:
Pump pressure water bar 93
Pressure pump outlet @ Qiec bar
Pressure gun outlet @ Qiec bar 84
Retaining pressure* bar -
Flow. Qiec l/min 6,1
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 240V/1ph/50Hz/9,6A/2,2kW
Control voltage V 240
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421566

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 10
Parent item no: Description:
107145002 GERNI NEPTUNE 2-16 240/1/50/10
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 1,8
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water 25030
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 ST GUN - GERNI W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 1080 BEND - GERNI
Secondary Lance Type None
Hose HP-Hose DN6X10M for swivel quick 3/8"
Guaranteed sound power 91
Impactfactor calculated 1,4
Vibration ISO 5349, lance 1 / lance 2 13,3 / -
Protection Class IPX5
Machine incl. standard acc. 110
Size - Machine alone L x W x H 607x688x1000

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 11
Parent item no: Description:
107145003 NEPTUNE 2-26 EU 230/1/50/16
Service data Unit Value
Model
NEPTUNE 2-26
Item no. 107145003
TECHNICAL DATA
PUMP:
Pump pressure water bar 134
Pressure pump outlet @ Qiec bar 124
Pressure gun outlet @ Qiec bar 120
Retaining pressure* bar -
Flow. Qiec l/min 8,17
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 230V/1ph/50HZ/14.5A/3.4KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421566

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 12
Parent item no: Description:
107145003 NEPTUNE 2-26 EU 230/1/50/16
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.4
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0340
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 940 BEND
Secondary Lance Type None
Hose HP Hose DN6x10 w/swivel, Quick 3/8",155°
Guaranteed sound power 91
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 110
Size - Machine alone L x W x H 607x688x1000

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 13
Parent item no: Description:
107145004 NEPTUNE 2-26X EU 230/1/50/16
Service data Unit Value
Model
NEPTUNE 2-26 X
Item no. 107145004
TECHNICAL DATA
PUMP:
Pump pressure water bar 135
Pressure pump outlet @ Qiec bar 122
Pressure gun outlet @ Qiec bar 118
Retaining pressure* bar -
Flow. Qiec l/min 8,17
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 230V/1ph/50HZ/14.5A/3.4KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421566

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 14
Parent item no: Description:
107145004 NEPTUNE 2-26X EU 230/1/50/16
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.4
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0340
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 940 BEND
Secondary Lance Type None
Hose HP hose DN6 15 for HW and w/swivel, 155°
Guaranteed sound power 91
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 112
Size - Machine alone L x W x H 607x688x1071

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 15
Parent item no: Description:
107145005 NEPTUNE 2-25 GB 230/1/50/13
Service data Unit Value
Model
NEPTUNE 2-25
Item no. 107145005
TECHNICAL DATA
PUMP:
Pump pressure water bar 85
Pressure pump outlet @ Qiec bar 71
Pressure gun outlet @ Qiec bar 67
Retaining pressure* bar -
Flow. Qiec l/min 10
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 230V/1ph/50HZ/12.4A/2.9KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421566

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 16
Parent item no: Description:
107145005 NEPTUNE 2-25 GB 230/1/50/13
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.9
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0530
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 940 BEND
Secondary Lance Type None
Hose HP Hose DN6x10 w/swivel, Quick 3/8",155°
Guaranteed sound power 90
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 110
Size - Machine alone L x W x H 607x688x1000

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 17
Parent item no: Description:
107145006 NEPTUNE 2-25X GB 230/1/50/13
Service data Unit Value
Model
NEPTUNE 2-25 X
Item no. 107145006
TECHNICAL DATA
PUMP:
Pump pressure water bar 89
Pressure pump outlet @ Qiec bar 69
Pressure gun outlet @ Qiec bar 65
Retaining pressure* bar -
Flow. Qiec l/min 10,72
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 230V71ph/50Hz/12.5A/2.9KW
Control voltage V 230
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 2800
Electrical diagram no. 106421566

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 18
Parent item no: Description:
107145006 NEPTUNE 2-25X GB 230/1/50/13
Service data Unit Value
BOILER:
Boiler power input kW 35
CO ppm
75
Exhaust temp °C 0
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 3.1
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 10,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0530
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 940 BEND
Secondary Lance Type None
Hose HP hose DN6 15 for HW and w/swivel, 155°
Guaranteed sound power 90
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 112
Size - Machine alone L x W x H 607x688x1071

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 19
Parent item no: Description:
107145007 NEPTUNE 2-25 KR 220/1/60/15
Service data Unit Value
Model
NEPTUNE 2-25
Item no. 107145007
TECHNICAL DATA
PUMP:
Pump pressure water bar 117
Pressure pump outlet @ Qiec bar 109
Pressure gun outlet @ Qiec bar 105
Retaining pressure* bar -
Flow. Qiec l/min 8,25
Suction height dry m -
Suction height primed m -
Pump type NA2
Number of pistons 3
Piston type Full Ceramic
Stroke mm 1
Pump oil type Agip Rotra
Pump oil amount l 0,2
ELECTRIC:
Electric data V/ph/Hz/A/kW 220V/1ph/60Hz/14.3A/3.2KW
Control voltage V 220
Highvoltage (HV) test voltage kV 1,5
HV Insulation resistance MΩ1
Earth circuit resistance Ω0,2
Pump revolutions rpm 3360
Electrical diagram no. 106421565

B
Technical data
NEPTUNE 1&2_EN_Ver.2.1_45/2014 20
Parent item no: Description:
107145007 NEPTUNE 2-25 KR 220/1/60/15
Service data Unit Value
BOILER:
Boiler power input kW 40
CO ppm
75
Exhaust temp °C 145
Ambient temp. @ Burner values °C 20±10
Fuel tank (Boiler) l 17
Boiler fuel consump.@∆T=45C 2.4
Burner efficiency % 92
Oil nozzle 0,75 60H
Oil nozzle size 0,75
Oil pressure bar 13,5
Fuel type Diesel
UNIT DATA:
Nozzle size, water NT 0350
Max. Inlet temp. (primed) -
Max. Inlet temp. (suction) -
Max. Inlet temp. (pressure fed) 40
Gun Type ERGO 2000 STANDARD GUN W/O HOSE SWIVEL
Primary Lance Type UNIVERSAL PLUS LANCE 940 BEND
Secondary Lance Type None
Hose HP Hose DN6x10 w/swivel, Quick 3/8",155°
Guaranteed sound power 91
Impactfactor calculated 0
Vibration ISO 5349, lance 1 / lance 2 0 / -
Protection Class IPX5
Machine incl. standard acc. 110
Size - Machine alone L x W x H 607x688x1000