neptune pe/de - JetWashDirect Ltd
Contents
1. L LE Ls n d 1 IE 5 H zi ED Ier d ZEN w wi gt m1 4 s bh SE H m ka Li D w T Ee Wi a E T CS e m LI d mmm 1 m _ a P LH mI r D mui E hz MES ARE Pu Be E 8 os D ma ES mE De GE ege ven HI Ve E Wi at 7 a L LI E wt A Q 5 A A d 7 a z i z z H r ETT E m fa a E cn femp Ve Ge 4 Litt am TA ME DE MELLE une 4 1 x F d Ge wi L z 5 ER nouem t V IW I WK a A LIF ES VE s Ie s D Tx Ne s EE 1 3 A Si d es m 1 WI I KA e Wa A M A T Vd wn az vi Dy wi H we Kd B n A m d ae X Gel Te E Kr GO n I Mai E d Vu Ta LI d LS um ur DL n 1 eng Jee 3 ec I e G Kei A i um 8 d Hr A LI H a m Let d ch LE gef Wei d e d ist mm UN TUR lv d E CS esa 5 ma om A w a Bes D ST MT 1 w2. Kotor Farar lAnasserl schalter Sheurtrafa curdtrafo Tier klemm Faget until Shop Spulie imot Brest DK 9560 Hadsund EL DIAGRAM NEPTUNE 7 72DE Mits Jetwash Direct Itd NEPTUNE 7 720 3 OF 3 FRACS nnFrBaur gechmpnus Capteur de tenperature Indiceteur dedebt 1 Lange Pedut d esundcalgur dg 2 Interrupteur Conpteur Berctrangue Capteur de tlanne combustible Sich d hule Deier tenperateur noteur Deter De tenperdteur porge Condensal eur fil icmnandyy fil fin Fuse Til Tin commanded Generator Binirareur 731 Bahari Real de ot Tage de nirarreur Moteur Moteur d ventlareur de Killer Moteur de Buga Interrupteur Transfert uer Trans eral er dalun FST eur BrulTa da rareurdanun t nm us Electrovanne pressan mur mter Ponpe a Fuel Eretatning far 106427171 ver A 3073 92 Notes a NEPTUNE PE DE en Ver 1 0 October 2010 93 Jetwash Direct Itd JETWASH DIRECT LTD www jetwashdirect co uk sales jetwashdirect co uk Jetwash Direct Itd
3. Sikrng prnt H ni 01 03 D KE rng ikrhg print 17V D GMIBratar 23 BaHeri rele Start rola Motor 607 Note Mater fig rer Hle afbryder Tyretrarn Tandirafu Timer Timer Magnghranti Stop spile Inatarl Br ands tof pun pa NEPTUNE PE DE_en_Ver 1 0_October 2010 EFlarirank cantroler LEO board Tang sinar safety ternal vartch Figumalrrh catch Hoar counter Rane senum Level switch furl Patar ob Tharnn Moto Thermo switch tax itar Fuse l cmtroler Fuse Fuse LEO baard Alternator 18 Generator 2307 Hatters Glo relay Ghartor rolay Centector Iran Motor Fan Matar Gow plug wich Control traraforner ignition Harmnr nu Tier Thur ong Step strip Plug Magnet value Shop purp DEITCH gFeurelaktrenik LED plating Temperatur sensor Sra ee ter 1 Thernnarherung STH schalter Shundercebler Aann 0 4 Scheiner bronnstett Farara whaler Thempt ler iint pe There Feinsicherung Fengknerung Corgrater TY OI Batter Dihan ralas ANAS FRAI
4. Dismount locking ring on the rotor shaft The wobble disc is easily dismounted with puller no 1205715 and special legs no 1206150 1206168 Do not forget to remove the key before dismounting the D bearing cover Check bearing surfaces for wear If in doubt replace kit complete after approx 2000 hours When mounting the D bearing cover comp lete protect the U sleeve with tool no 1206598 which is placed on the shaft befo re placing the cover Tool 1206598 Pittings When mounting the wobble disc lubricate the bearings with oil The big roller bearings Check the bearing surfaces for wear As are identical Do not forget to mount the long as the wear is even and shiny without pittings or grooves the wobble disc can be NEPTUNE PE DE en Ver 1 0 October 2010 circlip on the rotor shaft Refill with 1 oil type Castrol Alphasynt ISO 150 53 Jetwash Direct Itd ALTO oervice Repair NP5 Pump Valve cover amp seals Motor Pistons amp oil seals Pump housing NEPTUNE PE DE en Ver 1 0 October 2010 54 Jetwash Direct Itd ALTO oervice Repair NP5 Pump Dismount the brass plug on the cylinder head with a 21mm fixed spanner and remove the valves Do not scratch the inside of the valve chamber during removal When you replace the valves give the o rings an inspection for damage before mounting NEPTUNE PE DE en Ver 1 0 October 2010 55
5. IN 909 RWS C3 Pump Thrust collar Torque 37 Nm Oil sleeve secondary sleeve Spacer ring Crovn Drain off the oil Loosen the 8 bolts gradually because of the spring load Special box head 1206762 may be used Mount new O rings on studs with tool no 1206812 Always replace secondary sleeves when replacing pressure sleeves Check that there is a free passage from the drain holes secondary sleeve NEPTUNE PE DE en Ver 1 0 October 2010 Spacer ring 2 e 4 u 7 x j h e d Back up ring 51 Jetwash Direct Itd ALTO Service Repair C3 Pump Carefully tip out the oil sleeves with an adequate screwdriver and discard them Be careful not to scratch the surface Before mounting the new sleeves it will be a good idea to moisten the sleeves with soapy water Mount new oil sleeves with punch no 1220429 Carefully knock or press them home Oilsleeve LP HP Check the piston for wear Y the pressure area the area fPressure area rides on wobble disc or oil sleeves Check the ceramic for cracks Remo ve any coating Pressure area touches Stainless steel Ceramic the bearing disk NEPTUNE PE DE en 1 0 October 2010 52 Jetwash Direct Itd ALTO Service Repair C3 Pump
6. 85 NEPTUNE PE DE en Ver 1 0 October 2010 Jetwash Direct Itd Nilfisk ALTO Wiring diagrams 3 Ue rn EH EH DANSK sikring Tendings kentakt Pumpe alle swlFch Motor olie switch Startmotor Batteri Ladespele Regulator ensretter Termostat pumpe Niveau Time Faller Start rel Elbaks sid epr int print Temper atur Overhedstermostat Flawswitch 1 Lys f ler Flawswltrh 2 Hievau diesel kondensator Sikr ing Alzser moter Drejeaforyder Styretransformer Tendtransformer Sami te IMagnetwentil alie NEPTUNE PE DE en Ver 1 0 October 2010 ENGLISH Main fuse Engine swilch Pump all level switch Mator ail level switch Starter motor Battery Charge coil Requlatarsr eetlfler Thermostat pump Pump oil level switch Hour meter Start relay E Electronic cantroler baard Temperature Sensor Ferminal switch Flowswitch 1 Flame sensar Flawswitch 2 Level switch fuel Capacitor Fuse Blower matar Rotary switch Contral transformer Ignitian transtar Connection Glock Solenoid valve DEUTSCH Sicherung Undschalter Pumpen Olstandschalter Motor Olstandschalter Anlasser Batterie Ladespule ae hutz2sehalter gleich ichFer Themperatursensor pump Swimmer 5 pump engl Stundenzaler 4nlassermagnerschalter achaltkasten St euerelektranik LEO platine Temperarursensor
7. vawe DEUTSEH i achrlrhtan Schutzsthalter fondschalrer slert enhet s tandschall r Lades ple 2 4 Anlassermagnelschalter Salterk Thenperstirsensor pump Shundenzdler Slevereles Panik LEE Tenperatursensar SIrommngswsdrler Thernas cher Strange Ranmnsande rranistott onderialor terung Srennergeslasenolor Jdrahschallar Slepertrato sanrmelklenne Magnet venil Jetwash Direct Itd NEPTUNE PE 1 Cylinder Honda Page 3 of 3 FRANCAIS Bebe pp ale Regulater Contacteur d arret Unite dalerte d huile Contactaur niveau d tela de charge dillunaze gauche Gauge gauche Fusble thermique Tenperateur Conpeur heures Contraleur electronigue LED electronqee Capteur de temperature Indicateur de debit a signsux desu Indica esr de deat 1 Capteur de flamime amp ulamale Plotter combustible Condensal er Fus ble fi Thi de ventilatecr du brilar Fatary intarrzplar Transtermareur dallunage Terminal ElecFrovanne Wiring diagrams NEPTUNE 5 85PE 1 OF 3 e t lt o ver 3 F
8. 73 NEPTUNE PE DE en 1 0 October 2010 Jetwash Direct Itd Nilfisk ALTO m ry a wa T ee s LER 1 LIT e e e U l Wiring diagrams DANA Ensr etter amp ikri Regulator Tendings kentakt Dlie cantral rel Hotar olie Ladespole Tzndspole Tendr Startmotar Start rel Barten Termostat pumpe Niveau purpeplip Timeteller SP oprel Styr epr int LED print Temperatur Flpmuswilch 1 Overhedstermostat Flawswitrh 2 Lus diesel Kondensater Sikr ing Bleser mehar Ore jeafbryder Sturetransformer Tandtrans Former Samlemufte alie NEPTUNE 1 0 October 2010 ENGLISH Rectifier Main fuse Regulator Engine 4 witch Gil alert unit Matar ail level switch Charge coil Ignitian coil Spark plug Starter matur Start relay Battery Thermostat pump Pump oil level switch Hour meter Relay stop Electronic controler LEO baard Temperature sensor Flowswitch 2 ty Ferminal switch Flowswitch 1 Flame sensar Level switch fuel Capacitar Fuse Blawer motor Rotary switch Control transformer Ignitian transfer mer Connection block Solenoid valve DELTSEH eich chter Sicherung Schutzsehalter Undschalter alert einheit Olstandschalter Ladespule Z ndspule AUndkerze Anlasser
9. 49 91 3975 5 ANN Ldn 75 NEPTUNE PE DE en 1 0 October 2010 Jetwash Direct Itd x E O E Nilfisk ALTO NEPTUNE 5 54 AND 7 61PE 2 OF 3 1418 17 3175 5 ANN Ldn WyHoyig 1 Din 88 40 xum JU 7 J BA AQSUAS auo j FTAD 01 2 2 04 Aaedun tas ADEE JB Tes CL LA SPA 0905 PI __ ar 76 NEPTUNE PE DE en Ver 1 0 October 2010 Jetwash Direct Itd x E O E Nilfisk ALTO NEPTUNE 5 54 AND 7 61PE 3 OF 3 L IU EH SE 88 40 xum 49 91 3975 5 ANN Ldn 77 NEPTUNE PE DE en 1 0 October 2010 Jetwash Direct Itd Wiring diagrams NEPTUNE PE 1 Cylinder Honda Page 1 of 3 NEPTUNE 1 13 lt GE c E D i NEPTUNE PE DE en Ver 1 0 October 2010 18 Jetwash Direct Itd x E O E Nilfisk ALTO t Up 7 VO 34 INNLdIN 1 WWUDVIO 13 iK A NEPTUNE PE 1 Cylinder Honda Page 2 of 3 a el eo et Pm Wis L AINE ayy CS s JY ADEZ Ag 79 mae
10. Jetwash Direct Itd Service Repair Be careful when you dismount thrust col lar because you can easily damage the surface inside Give the thrust collar an inspection before mounting When mounting the sleeves and the spacer remember lubricating When dismounting the suction sleeves use a screwdriver to tip out the sleeves Do not reuse the sleeves Clean the thrust collar and lubricate before mounting the sleeves as shown in the illustration Inspect the the thrust collar for marks When you mount the cylinder head lubricate and mount it with your fingers tighten the bolts in the shown sequence Use a 6mm hexagon wrench NEPTUNE PE DE en Ver 1 0 October 2010 56 Jetwash Direct Itd yw Service Repair 5 Piston 8 Seal To inspect the plunger for cracks Spray the inside of the plunger with fast evaporating cleaner such as a brake cleansing agent The brake cleansing agent will take a second longer to evapo rate from the crack thus making the crack visible Carefully inspect and replace as needed O rings and backup rings on the plunger rod prior to reinstalling the plungers Backup ring O ring 1 4 Copper washer Torque 106 Inch pounds Brass slinger plate 8 8 ft lbs 13NM Oil seal Also clean the brass slinger plates before reinstalling the plungers Do not re use the copper washers Use one drop of medium s
11. e E Reed Switch Flow Switch Second w Switch First Plug with Shaft Flow switch Plug with Shaft Water supply connected to the machine Water from the pump is pressed through the high pressure hose to the first flow switch When water is entering the first flow switch the piston with magnet is pressed to the top of the flow switch housing and the reed switch is making contact and closing the circuit Reed switch is a NO contact Water is now pressed through the second flow switch the piston with magnet is pressed to the far end of the housing and the reed switch is making contact and closing the circuit When the spray handle is released and the water flow stops the flow switch pistons will move away from the reed switches and the will brake off the circuit and the burner will stop When the water flow stops the piston in the first flow switch will fall down and be stopped by the plug with the shaft The plug with shaft is installed to reduce the movement of the piston The signals from the two flow switches must come simultaneously MAX difference between the two signals are 4 seconds The signals from the flow switches are controlling the fuel pump solenoid valve This to make sure that the burner is not starting if there is no flow of water through the heating coil NEPTUNE PE DE en Ver 1 0 October 2010 35 Jetwash Direct Itd Nilfisk ALTO Function 3 V Cd 4 5 L
12. Green LED and red LED flash si multaneously v NEPTUNE PE DE en Ver 1 0 October 2010 Water tap closed or wa ter flow inadequate Detergent tank empty Pressure rate control or Vario Press set for too small amount of water Machine scaled up Leakage or impermissi ble operating status through brief operation opray pistol leaking HP hose HP coupling or pipe leaking Detergent tank empty Filter clogged in water intake HP pump sucking in air Jetwash Direct Itd See Chapter F 3 3 F 3 5 and G 3 4 Cold water mode is possible Requirements in Chap ter B Refill detergent or set the SDR valve to 0 Set the pressure rate control or Vario Press for a higher water flow Descale the machine The machine cuts out after being briefly oper ated three times Reset set the main switch to Off Operate the pistol for gt 3 s Check the spray pistol Tighten the screws re place the HP hose or pipe Refill detergent Clean the filter Correct leaking points 39 Troubleshooting D i gt Green LED and red LED flash al ternately Green LED flashes slowly amp red LED flashes fast v Motor machine over heated MT has trig gered Thermal release B3 has tripped 24 Vac fine wire fuse F2 has blown Fault in fuel or ignition system burner fault Flame probe option sooted up Set the main switch to Off Allow the machine to c
13. aci Ae Ee ee I d d h AN CH PP di lI ne AE Tt A Ze 4 CX p A f Tis oa K w E 1 u T z UE ce UN A ar A E Ta PE 1 T Si m T T t H 1 7 T s L F gt fl Ei a uer h DESS a PL 1 as OF ga A ch P LA K 1 exchanger schematic Heat exchanger NEPTUNE PE The heat exchanger is the func tional link between the heating sub system and the water subsystem In Hot water mode the burner fan 1 draws in air and conducts it lat erally into the heat exchanger where it is routed upwards between the two Jackets to the baffle plate 2 This preheats the air before it mixes with the fuel spray from the fuel nozzle 3 Cold water is fed to the inner circuit in which the temperature is highest This reduces in as much as possi ble any condensation on the sur face of the heating coil 4 At the same time fuel is drawn in from the fuel tank by the fuel pump 5 through the filter 6 The fuel is conducted by the solenoid valve 7 to the nozzle stock 8 with the fuel nozzle 3 If no combustion is needed the fuel goes back to the tank on the return line 9 The
14. mese ly CX 405195 aynjJgJadua Jetwash Direct Itd NEPTUNE PE DE en Ver 1 0 October 2010 Nilfisk ALTO NEPTUNE PE DE en Ver 1 0 October 2010 wi DES D LU ID gt mn c RI c c o n wm mar fN of kl Ei GEM mmm EH A1 2 Bl B B3 1 Wiring diagrams DANSK Ensrattar Regulator Trndngs bantakt rez switch Lates pale Tandspole Tzndr r Startnetar Start rela Termasl af purmpeolle Tineta ler 5 print Flowsertch 2 1 Le Tiler 0658 Konderrs at F F z F3 Skrim H1 vi Ti T XI TI Blesernotor Shyretransrormer armen Sanlenette Masnetventi die ERISH aln pese Regulater Engne switch Mert unr Oi switch harge call nition call plug Starter motor Start relay Thermas penp all lewel switch Heer meber Eectrenk contraer LED aard chene 8 HFawzwibch 2 G fke rnnal switch A Hate sensa Level fuel Rotary switch Rotary switch Central Tanstormer Transtarmer Commection lock
15. 0650 NEPTUNE PE DE_en_Ver 1 0_October 2010 7 Jetwash Direct Itd Technical data ri NEPTUNE PE Power HK RPM 10 3600 16 3500 SES Motor RPM adjusted RPM 3530 3500 Motor oil type SAE 15 40 SAE 15 40 CCM Cm3 406 185 185 Water Quantity high pressure l min 13 5 18 7 meter Suction capacity feeded Fuel pressure bar 10 Se Fuel consumption dt 45 c kg h 3 9 z content mm 10 5 5 Soot rating 0 Efficiency 92 5 2 Onboard fuel tank Litre 57 57 Heater rating kW 81 Delta T working pressure S 81 76 Type t16W 75 t16W 75 S Effect W 1000 1000 RPM and Boiler RPM 2825 2825 PUlley Size SPZ 63 1 SPZ 60 1 Belt dimension Motor Gen SPZ 670 SPZ 670 Width Weight kg Sound power level Lwa Db 110 112 9 High pressure hose DN8 m 15 15 nozzle 0450 0650 NEPTUNE PE DE en Ver 1 0 October 2010 8 Jetwash Direct Itd Technical data NEPTUNE PE RS _______ 200 CCM Pump pressure Water Quantity high pressure l min 19 5 meter Suction capacity feeded Fuel pressure bar 12 5 Fuel consumption dt 45 kg h 5 H content 10 5 Soot rating 0 1 Efficiency 92 Onboard fuel tank Litre 57 Heater rating kW 111 Delta T working pressure gt 76 t1
16. 3 EL DIAGRAM NEPTUNE 5 85PE Honda 2cyl i Hobariak s SSE SES SS s T a nm z az n m DD e D m gt D gt a om rm 19 rm ec 2 Ap 19 NEPTUNE PE DE en Vert 0 October 2010 Jetwash Direct Itd iagrams d iring Nilfisk ALTO NEPTUNE 5 85PE 2 OF 3 Cg V 422 6 3 183 666 120 WYYO IO 13 o ml d uu 105195 91241416 04 6 2 04 Jadunf jas Bul Bue mp AS L qodung qw TET an 82 NEPTUNE PE DE en Ver 1 0 October 2010 Jetwash Direct Itd Nilfisk ALTO Wiring diagrams Styraprint LED print Ad 81 Tenperatur Fler B ten 1 Charhadetarnos tat B teh 2 BS olk HT Flamef Her DN Murau diesel Motoralia swith HT Ternafsier 01 Ensetter HPP A T SPI ent A3 Skring kantrolbox Shring LED print 01 ic DK 2317 Batter Li Tanck poe Li Tedbapge Hi Mut er Hoto ke l WEI Hote Styra trato Generi alle Sto
17. 7 61PE front side NEPTUNE PE Square DE machines hole in the fuel tank Water outlet Honda Motor C3 pump Water Break tank OPTIONAL Water regulator Anti Scale container OPTIONAL Wheels OPTIONAL NEPTUNE 7 61PE front side NEPTUNE PE DE en Ver 1 0 October 2010 11 Jetwash Direct Itd Construction Overview NEPTUNE 7 61PE NEPTUNE 7 61PE boiler top Flow Flow Temperature Temperature sensor Flame sensor switch switch Sensor boiler exhaust Electrodes Fuel nozzle NEPTUNE PE DE en Ver 1 0 October 2010 12 Jetwash Direct Itd Construction Overview NEPTUNE 7 61 NEPTUNE 7 61PE backside 4 W L K ks D EN Generator 230V Charging relay Top cover NEPTUNE PE DE en Ver 1 0 October 2010 13 Jetwash Direct Itd Construction 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 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 Fuel pump access through the square hole on the right side of the fuel tank Honda motor 5 pump Temperature sensor pump Safety valve This safety valve is used only on 5 Oil glass Water Unloa 85PE and 5 wilevel inlet der 51DE becasue switch the unloa
18. Ther mesicherun Stromnungswachter 1 Flammsnnde Stramningswachter Schwimmerschalter brennstoff Kandensatar Feinsicherung Hrennergeblasemeter Orehsehalter Steuertrato fundtrato Sammelklemme Magne NEPTUNE 5 51DE 3 OF 3 FRANCAIS Fusible Contacteur d arret moteur lemarrgur Batterie d charge Regulateursredresseur Fusible Thermique pompe Detec de temperateur Compeur heur es Relais Controleur electronique LEO ele chronique Capteur de temp rature La mpe a signaux Reduit d Sau Indicateur de debit 4 Lapteur de flamme Indicateur de d hlt Automate flotteur cambustible Condensateur Fusible fil fin Moteur de ventilateur du br lgr Rotary interrupter Transtar Transfar mateur dallumage Terminal omnibus Electravanne _ Je me s a rm Jetwash Direct Itd a Hr m EL DIAGRAM NEPTUNE 5 510 106472125 ver Zur 86 JP O 30 V 6608 3099 1 ICH 0 13 d o SH 500 N 2 D z _ T paso aadun 185 AR d iring 101243490 Nilfisk ALTO 87 Jetwash Direct Itd NEPTUNE PE DE en Ver 1 0 October 2010 iagrams d iring Nilfisk ALTO NEPTUNE 7 66DE 2 OF 3 t JO y BBnu 30
19. With the temperature setting knob it is now possible to set a new service interval The reading is done by the LED s 4 5 6 7 and 8 where 4 is 100 hours 4 5 is 200 hours and so on up to 500 hours when all LED s are on If setting is not changed for 3 sec the setting is saved This can be seen when the chosen LED s are flashing Machine must now be switched off and the jumper removed from X5 Default service setting from factory is 200 hours NEPTUNE PE DE en Ver 1 0 October 2010 70 Jetwash Direct Itd an Adjustment Test Boiler H 2 19 d LA P d KA E Heating system Overview 1 Ignition Transformer 4 sensor 2 Ignition cords 5 Fuel nozzle 3 Ignition electrodes 6 Air distributer Fuel nozzle Fuel nozzle NEPTUNE en Ver 1 0 October 2010 71 Jetwash Direct Itd x E O E Nilfisk ALTO NEPTUNE 5 46PE 1 OF 3 o dh rd 149 5 1 13 RSC und Tr dL 72 NEPTUNE PE DE en Ver 1 0 October 2010 Jetwash Direct Itd x E O E Nilfisk ALTO NEPTUNE 5 46PE 2 OF 3 Jd3 5 JMfllIdJM ELM Wy 3nid 13 Din 88 40 um Jo Q JA SIT Bud 4 5 stu 25974 20 4 __ 04 E P 01 48 ADEA JB Pu
20. full RPM Slowly close the valve on the test manometer and read the pressure when the safety valve opens That will be the pressure just before the pressure drops The opening pressure for the safety valve must be 25 30 bar above normal working pressure To adjust the opening pressure loosen the lock nut pos 1 with a 22 mm Open ring spanner Then adjust the safety valve by turning the adjustment screw with a 6 mm Allen Key When turning clockwise opening pressure increases and counterclockwise it decreases NEPTUNE PE DE en Ver 1 0 October 2010 66 Jetwash Direct Itd Adjustment Test NP5 pump Adjustment of Unloader system Turn the black handle clockwise Using a screwdriver or similar tool as far as It can to remove the cap on of the This is max pressure adjustment unloader 13 mm Box spanner Loosen the lock nut on the pres Adjust the pressure with a 7 Hexagon sure adjustment bolt Use a 13 Allen Key the following way mm box spanner otart machine with correct HP nozzle Loosen unloader until pressure drops then turn 1 2 turn clockwise to obtain full pressure again NEPTUNE PE DE en Ver 1 0 October 2010 67 Jetwash Direct Itd Adjustment Test NP5 pump Adjustment of Unloader system Mount the cap on top of the unloader Now the correct adjust ment of the unloader is done By turning the handle counterclock wise you can reduce the pump water volume and
21. ignition transformer 10 acti vated in Hot water mode gener ates ignition sparks across the elec Fig D 19 trodes 11 to ignite the fuel spray i This process is monitored by the 1 Burner fan 10 Ignition transformer flame sensor 12 2 Baffle plate 11 Ignition electrodes In normal operation the hot exhaust 3 Fuel nozzle 12 Flame probe flows downwards and upwards be 4 Heating coil 13 Flue tween the piping of the heating coil 9 Fuel pump 14 Flame sheath 4 thus warming the water in the 6 Fuel filter 15 Flame funnel system 7 Solenoid valve 16 Insulation The exhaust exits through the flue 8 Nozzle stock 17 Water inlet 13 9 Fuel return line 18 Water outlet NEPTUNE PE DE en Ver 1 0 October 2010 36 Jetwash Direct Itd Nilfisk ALTO Function Safety Thermal Temperature Sensor in boiler exhaust Located in the heat exchanger outlet flue is a tempera ture dependent resistor Pt 100 functioning as a tem perature sensor If the temperature in the heat exchanger outlet actual temperature exceeds the temperature set point the so lenoid valve Y1 closes to interrupt the fuel feed The temperature sensor is only activated in Hot water mode The safety thermal release mounted on the heat exchanger water inlet is an absolute safety element on the heat exchanger If a fault is present e g all control and safety devices fails and hot water flows at high pres sure from the heat exchanger bac
22. the by pass valve is stocked and lead water to the suction side of the pump Water reduction When the water regulation G is turned counter clock wise the seat H opens and the water runs both to the outlet of the by pass housing and in by pass to the suction side of the pump The pressure K will fall depending of the size of the opening in seat H NEPTUNE PE DE en Ver 1 0 October 2010 32 Jetwash Direct Itd Nilfisk ALTO Function By Pass valve function NEPTUNE 7 61PE 7 66DE 7 720 im gt Ak k mi d 22772 all __ Start Su Fr Y DENS geen i Non rastume Operation The water from the pump 1 lead into the chamber A in the by pass valve From here the water passes through the holes B in the by pass valve pis ton and out to the high pressure nozzle When water is pressed through holes in the piston there is a pressure drop over the piston this means the pressure is higher on one side of the piston This will keep the valve cone D closed against its seat because the piston 1 fixed to the valve cone NEPTUNE PE DE en Ver 1 0 October 2010 Valve piston Water quantity ___ 1 ES requiat on valve Pressure duct Bypass chamber connacted to the sucton duct By Pass When the water consumption
23. thermo switch high pressure pump is output 15 on A2 connected to ground At the same time input F on the Honda motor is connected to ground and the Honda motor will stop IMPORTANT JUMPER ON A2 MUST BE MOUNTED NEPTUNE PE DE en Ver 1 0 October 2010 23 Jetwash Direct Itd Nilfisk ALTO Function Functional desription of Circuit Board A1 Datalogger mper Br DU posee jumper to 2 3 to B m B2 activate Flame sensor be LG I Operation Fuel Punp l Service Ant Stene EL DIAGRAM NEPTUNE 5 5 Handa 2cyl The circuit board used all NEP TNE PE DE machines is the same as used in NEPTUNE The only difference is the following bridges which are mounted on the circuit board in the NEPTUNE PE DE machines X4 5 to X5 6 oil level switch high pressure pump Oil level switch is moved to circuit board A2 X4 1 to X4 2 Anti stone X3 5 to X3 6 Thermal switch in high pressure pump motor NEPTUNE PE DE en Ver 1 0 October 2010 24 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of Circuit Board A1 Datalogger Set jumper ta 2 3 to activate Flame sensor 5 p GER EL DIAGRAM 106422122 NEPTUNE 5 5BPE Handa 2 ver A 2 of 3 Eratettet ar Control Circuit Board A1 is functioning the same way in all the NEPTUNE PE DE models The power supply to A1 is supplied by the 230V generator G2 which is driven by th
24. uer Trans gr 02 Pac Cor oe ent ombus Electravante interrupteur pour nateur Ponpa Eretatning far 1064271724 ver A 3073 89 iagrams d iring Nilfisk ALTO in m wm iis 5 j0 V J9 5 3021 4 INA Ld JN Gs 121229901 Gg LLI xj Een Q 0988 0 2 n Lt LLI 5 E 30 Ad Ty mnm n EA ADEA p HILWNOA HOH 401 HM s H Ch m 90 Jetwash Direct Itd NEPTUNE PE DE en Ver 1 0 October 2010 iagrams d iring Nilfisk ALTO 510 Y dea SI 3021 1 3NQLd3N 0 0079 29390 73 E Ej NEPTUNE 7 72DE 2 OF 3 1056096 aue ajeape 8 DI 01 7 0 J dun IR Foz X ji zB ol T E Ww ANY Af NM B P __ eeg IE LL _ ___ ___ CN LV RAB 91 Jetwash Direct Itd NEPTUNE PE DE en Ver 1 0 October 2010 Nilfisk ALTO Wiring diagrams Al 81 Br AS Bh N RN At D Steph LEO print reor 1 Cherhedsternotat Fit 2 Punpa ch Tine teller Hansi Ber Niveau deel Mart Tamoftar noter
25. you let go the key the key moves back to the ONT 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 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 lf 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 NEPTUNE PE DE en Ver 1 0 October 2010 20 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of NEPTUNE 7 66DE Charging Generator Set jumper closed OAT ____________ Nilfisk BR LTO m fr EL DIAGRAM 106422124 MSs NEPTUNE 7 66DE ver A 1063 P 159416 When the key 1 is turned to start the start relay is pulled and the motor starts Then let go the key and it moves back to the ONT position The motor oil pressure switch B10 is a normally closed switch In closed position motor not run ning the switch is connected to ground When th
26. 6W 75 5 Effect W 1000 S RPM HP and Boiler RPM 2825 8 PUlley Size SPZ 63 1 Belt dimension Motor Gen SPZ 670 Width Weight kg 510 2 o Sound power level CE Lwa dB 99 9 High pressure hose DN10 m 15 5 HP nozzle 0640 NEPTUNE PE DE en 1 0 October 2010 9 Jetwash Direct Itd Construction Overview NEPTUNE 5 46PE and 5 54PE The NEPTUNE 5 46PE is designed with a high pressure pump a NEPTUNE 5 boiler and a HONDA GX340 motor 5 54PE has a Honda GX390 motor VN y z A small special hexagon key for b easy adjustment of the fuel pressu re is placed in the electric box in all NEPTUNE PE Fuel pump access through DE machines the square hole on the right side of the fuel tank MAS PUNG Honda motor 230V Generator 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 NEPTUNE PE DE en Ver 1 0 October 2010 10 Jetwash Direct Itd Construction Overview NEPTUNE 7 61PE 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 anda NEPTUNE 5 boiler A small special hexagon key for easy adjustment of the fuel pressu re is placed in the electric box in all Fuel pump access NEPTUNE
27. 95 7 INMLdIN 66 1909 KY NDVIO 13 0996 34 ml OSM sen JOSUBS 0 z Of J duin jas _ Bue mp TEX EX __ XY E e WOR HUY aar dum pny 88 NEPTUNE PE DE en Ver 1 0 October 2010 Jetwash Direct Itd Nilfisk ALTO Wiring diagrams Al 81 Br AS Bh N RN BH atl D Steph LEO print reor 1 Cherhedsternotat Fit 2 Punpa ch Tine teller Hansi Ber Niveau deel Mart suite Tarnu noter konde Skrig Im Fi 1 iz 03 Ke m 51 T 07 13 Gkring ILED print fawuratar ify DE HY Baton rele diem el Moter tar Malo aforyder Gu Meld Tan dtrato Tine ELEIT Ehk E GHE alke Sto spala natur Br ences tof punpe NEPTUNE PE DE_en_Ver 1 0_October 2010 ENGLISH EFlarirank cantroler LEO board Tang sinar safety ternal vartch 2 catch Hoar counter Rane senum Level switch furl Farar ab aire Tharnn Moto Lepi itur Fuge el central gr Fuse Fuse LEO Ward 124 OC Battery 5 r
28. A into the by pass housing C The water runs through the bottom of by pass housing C and directely to the outlet Due to the water pressure the by pass piston B is pressed up and the seat E is closed By pass pressure Machine is started and the gun is closed By pass pressure When the gun J closes the pressure inside the by pass housing equalizes and the by pass piston B is pressed down by the tension of it s spring The seat E in the top of by pass piston opens The water runs from the pump outlet A into the by pass housing C Due to the closed gun J and the opening in the by pass seat E the water runs back into the suction side of the pump through the valve D NEPTUNE PE DE en Ver 1 0 October 2010 31 Jetwash Direct Itd Nilfisk ALTO Function D By Pass valve function NEPTUNE 5 46PE and 5 54PE By pass pressure The by pass pressure is determined of the spring tension in valve The tension is fixed and will bring out a by pass pressure in about 30 35 bar Valve A also secures the self suction ability The cut off pressure when the gun is released is determined of the adjustment screw When the screw is tightened the cut off pressure will rice and by loosening it the pressure will fall The safety valve has no function under normal circumstances The pressure of the safety valve is set to about 25 30 bar above the cut off pressure The safety valve will open if
29. Anlassermagnerschalrer HatFerle Themper aFursensnr pump awimmer Stundenzaler stop schalter St everelektranik LED platine Tempera Fursensor sir rmnings wachter Ther mesicherun afr mnungs warhter 1 Flammsende Schwimmerschalter brennstoff kondensator Feinsicherung Brennerqeblasemotor ler STeuertrata Sammelklemme Magne Fventil NEPTUNE 5 46PE 3 OF 3 FRANCAIS Redresseur Fusible Requlateur Contacteur d arret moteur Unite dalerte d huile Contacteur de niveau d huile Babine d charge dallumage gauche Baule gauche lemarrgur Relais Fusible thermique pompe Datec de temperateur Compeur heures Relais Controleur amp lgrtranique LED rFranique Capteur de temperature Inditareur de debit Lampe a signaux Reduit d eau Indicateur de d bit 1 Capteur de flamme Autemate flotteur combustible nndensateur Fusible fil Moteur de ventilateur du br ler Ratary interrupter Transtar marver Transfarmateur dallumage Terminal omnibus Electravanne _ Page lr AN oie Jetwash Direct Itd NEPTUNE 3 46PE em EL DIAGRAM er b 1011 74 x E O E Nilfisk ALTO NEPTUNE 5 54 AND 7 61PE 1 OF 3 L IU EH SE 88 40 xum
30. Function Functional desription of Circuit Board A1 Continued 3 5 xam 2 d 1 Datalogger z 23 Set jumper ta 2 3 to g s B activate Flame sensor 2 3 Y1 trier Ces ALTO DK 9560 Hadsund kia me P 622122 NEPTUNE 5 5BPE Handa 2 ver of 3 ar 5 5 5 5 5 The flame sensor B7 is controlling if the fuel is ignited and if it is the flame sensor can see the flame it allows the burner to burn If the flame sensor don t see the flame after 4 sec when S1 is in hot water mode the fuel solenoid valve will close and the burner will be stopped If the display is flashing in the LED s it can be due to too low RPM on the motor If the LED s are flashing it means that the voltage is too low to maintain the circuit board The flashing LED s means that the display is re starting all the time NEPTUNE PE DE en Ver 1 0 October 2010 26 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of Circuit Board A1 Continued EL DIAGHAM NEPTUNE 5 58 Handa Seil Control Circuit Board A1 Control Circuit Board Pos 1 The heating and ON OFF switch 1 Pos 2 Heating Relay K2 Pos 3 LED s Pos 4 Fuse Self resetting Pico fuse Pos 5 Fuse Pos 6 Fuse NEPTUNE PE DE en Ver 1 0 October 2010 Circuit Board A2 A1 Circuit board A2 has LED s for the motor e g water temperature motor oil
31. NEPTUNE PE DE ALTO Why Compromise Service Manual NEPTUNE PE DE en Vert 0 October 2010 Jetwash Direct Itd Safety instructions Technical C Construction D Function F Service Repair G Adjustment Test 63 71 H Wiring diagrams 72 92 Jetwash Direct Itd Index NN A Safety instructions 5 B Technical 6 C Constrution Overview Unit Immer nnne 13 D Function 8 24 02 18 iii POD 24 CNIS 28 By pass valves Unloader 31 FloW OWN C 35 MOALE EE 36 E Troubleshooting ei Ela 38 F Service Repair E 42 48 saji l li o 54 Heat Exchanger 59 61 EE 61 eil Tue E 62 G Adjustment Test e TE 63 Ee 66 NEO aie 67 Heat Evchanger 69 H Wiring diagrams 72 NEPTUNE PE DE Ver 1 0 October 2010 3 Jetwash Direct Itd Preface aN This service manual contains detailed description of the main repair work on the Hot Water High Pressure Washer NEPTUNE PE DE If operating err
32. Overview of the parts inside the D bearing cover Fig F 28 Wobble disc removal Demount the wobble disc screwing a 1 6mm bolt into the threads Tighten the bolt against the motorshaft and pull the wobble disc out 46 Jetwash Direct Itd yw Service Repair D bearing cover Fig F 29 D bearing cover The D bearing cover is mounted to the Motor by four 6mm bolts When the bearing is damaged always replace the complete D bearing cover NEPTUNE PE DE en Ver 1 0 October 2010 NA5 Pump Fig F 30 Oil sleeve The oil sleeve in the D bearing cover can be demounted carefully using a screwdriver Mount the oil sleeve by using an adequate box spanner and a fiber hammer 47 Jetwash Direct Itd ALTO service Repair C3 Pump NS W ki N NEPTUNE PE DE en Ver 1 0 October 2010 48 Jetwash Direct Itd ALTO Service Repair Mandrel no 1216506 NEPTUNE PE DE en Ver 1 0 October 2010 49 Jetwash Direct Itd yw Service Repair C3 Pump Duct Mounting of textile sleeves by means of tool no 1220090 It is an advantage if the sleeves havebeen in a water bath for 3 4 hours before mounting them Do not forget to blow air through the ducts NEPTUNE PE DE en Ver 1 0 October 2010 50 Jetwash Direct Itd ALTO oervice Repair Washer
33. d Fuel pressure bar 12 10 _ Fuel consumption dt 45 G kg h 3 9 3 9 content min 10 5 10 5 Soot rating 0 0 Efficiency 92 92 3 Onboard fuel tank Litre 57 57 Heater rating kW 68 81 Delta T working pressure C 75 81 t16W 75 t16W 75 5 Effect W 1000 1000 RPM HP and Boiler RPM 2825 2825 6 PUlley Size SPZ 63 1 SPZ 60 1 Belt dimension Motor Gen SPZ670 SPZ670 Wiath S Sound power level CE Lwa Db 105 105 9 9 High pressure hose DN8 m 15 15 nozzle 0400 0450 NEPTUNE PE DE en Ver 1 0 October 2010 6 Jetwash Direct Itd Technical data NEPTUNE PE 42 Power HK RPM 11 0 3600 20 8 3600 CCM Cm3 389 670 Motor RPM adjusted RPM 3550 3340 Motor oil type SAE 15 40 SAE 15 40 400 Pump pressure bar 202 210 Water Quantity high pressure l min meter Suction capacity feeded Fuel pressure bar 11 E Fuel consumption dt 45 c kg h 4 6 z content mm 10 5 Soot rating 0 Efficiency 92 92 Onboard fuel tank Litre 57 57 Heater rating kW 87 Delta T working pressure S 70 70 Type t16W 75 t16W 75 S Effect W 1000 1000 RPM HP and Boiler RPM 2825 2825 PUlley Size SPZ 63 1 SPZ 60 1 Belt dimension Motor Gen SPZ 670 SPZ 670 Width Weight kg Sound power level CE Lwa Db 105 106 89 High pressure hose DN8 m 15 15 HP nozzle 0500
34. d Nilfisk ALTO Function NEPTUNE PE DE C3 PUMP The 4 piston pump 1 used in the NEPTUNE 7 61PE 7 66DE and 7 72DE SI xx 77772 SN ie Hui ll d Sard help wate WM Valve piston eo Water quantity ST Q regulation Safety valve Pressure duct suction canal Non returna By pass chamber connactad to tha sucton duct The wobble disc is mounted directly on the motor shaft Water is sucked through the suction valves and out through the pressure valves and the pis ton in the by pass valve The piston has two small holes where the water is running through in order to create a pressure drop which make sure the valve cone is closed during opera tion When water flow is interrupted the pressure rises until the safety valve opens Because of the achieved pressure drop the valve cone is pressed to open so the water re circulates at a pressure 10 bar Water quantity is regulated by a handle in the end of the by pass valve When turning the handle clockwise the by pass valve cone will be forced open so some of the water is re circulating in the pump NEPTUNE PE DE en Ver 1 0 October 2010 30 Jetwash Direct Itd Nilfisk ALTO Function D By Pass valve function NEPTUNE 5 46PE and 5 54PE Working pressure Machine is started and the gun J with correct lance nozzle is open Machine runs in working pressure The water is pressed from the pump outlet
35. der does not have a safety valve Generator Battery 12V NEPTUNE PE DE en Ver 10 October 2010 14 Jetwash Direct Itd Construction 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 8 and a NEPTUNE 5 boiler 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 Fuel pump access through the square hole on the right side of the fuel tank Battery 12V Generator Yanmar 230V motor Temperature sensor exhaust Temperature sensor water outlet Flow switch 1 and 2 5 pump Oil container w level switch Thermal dump valve NEPTUNE PE DE en Ver 1 0 October 2010 15 Jetwash Direct Itd 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 NEPTUNE 7 boiler 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 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 Tem
36. e motor This means that the motor must be running and running at full RPM before the 1 is working In cold water mode the 51 main switch can be in position ON or OFF If 51 is turned to the temperature area red the hot water mode is activated When 1 is turned to ON power is supplied through the fuse F1 to the microprocessor The micro processor is starting up and the 5 status LED is lightening up for 1 sec If there is a failure during start up the control circuit board goes into failure mode If the 51 main switch is turned to hot water mode and the spay gun is open and desired tempera ture set at 51 B1 temperature sensor is measuring lower temperature that the set point at 1 and B9 fuel level sensor is measuring fuel in the tank and B2 flow switch and B4 flow switch is register ing water flow the burner motor M2 is started and the ignition transformer T2 is started over the burner relay K3 A high voltage spark is generated between the electrodes in the burner The burner motor M2 is driving the burner fan which is blowing pre heated air into the boiler The self sucking fuel pump is pumping fuel pressure up to the fuel solenoid valve Y1 When the burner motor fan has been running in 1 sec the fuel solenoid valve Y1 opens and the fuel is pumped un der pressure to the fuel nozzle The atomized fuel is leaving the fuel nozzle and is ignited NEPTUNE PE DE en Ver 1 0 October 2010 25 Jetwash Direct Itd Nilfisk ALTO
37. e motor starts and the RPM increases the motor oil pressure increases the switch opens and there is no connection to ground anymore When no con nection to ground there is no ground on output 15 which means the motor runs If output 15 is connected to ground 5 sec after the key is turned back to ON position contactor is pulled and the fuel pump is disconnected for 9 sec done by TIM 2 Timer for motor stop motor stops If there is a failure on sensor B5 B 10 or B11 and by that output 15 is connected to ground the fuel pump will be disconnected in 9 sec and the motor will stop If the 12V charging is not functioning input 6 on A2 will be connected to ground IMPORTANT JUMPER ON A2 MUST BE MOUNTED NEPTUNE PE DE en Ver 1 0 October 2010 21 Jetwash Direct Itd Nilfisk ALTO Function Functional desription of NEPTUNE 7 72DE B STARTSWITEH TIMER ENG STOP TIM2 Nilfisk ms __ LE ALTO 9560 Hadsund _ a Ee NEPTUNE 7 72DE Mits ver 1of 3 rom _______ Eratettet ar When the key S1 is turned to the ON position the glow timer Tim1 and the glow relay is activated and the glow plugs R1 are heating and also the glow lamp on A2 is lightening After a short while the timer runs out and the glow relay opens Now the key can be turned to the start position and the starter coil Y2 red wire together with the holding coil Y2 white wi
38. e ne LI A Li F w 4 WW I LI 1 wi Wi Gebeier uin nir a ia Mounting plate Insolation NEPTUNE PE DE en Ver 1 0 October 2010 59 Jetwash Direct Itd Boiler Check the flame tu be marked with X and Y It is important that they are solid and complete Y is a part of the coil 8 and cannot be se parated Clean the coil Remove the outer top cover and mount the lifting tool over the two coil ends and fix it with the nuts Dismount the 4 nuts Arrows and hook up the crane and lift out the coil Burner Unit Fuel solenoid Fuel pump Burner motor Burner housing Fuel filter Fan Fan cover ee D S a change the isolation if needed 5 2 Es Burner fan and fuel pump NEPTUNE PE DE en Ver 1 0 October 2010 60 Jetwash Direct Itd ALTO oervice Repair Burner Electrodes Electrodes opring washer The electrode is adjusted from factory If the distance between the legs beco mes greater than 4 mm the electrode must be changed The electrode 18 is self adjusting the position on the nozzle by a spring washer 19 under the fixing screw 20 The flame sensor 9 must be fixed with 5 in the right position Clean the flame sensor NEPTUNE PE DE en Ver 1 0 October 2010 61 Jetwash Direct Itd ALTO Service Repair Maintenance Mainte
39. elm Contactor Matar Fani Motor Fani letartl Lo wich Central Hen Franznrnan Timer eng Step Terminal Plug Fagnet valve pil Chop Col Fuel purap DEITCH gFeurelaktrenik LED plating Temperatur sensor Sra ee ter 1 Thernnarherung STH schalter Shundercebler Aann s re Scheiner bronnstett whaler Thempt ler init pe Kordonsater Funszihurung Platnal Fenakierung Fansknarung Flatinel Gd 2 Batter Ans ag raais Kontakt er 9551555 Ariaxcar Sheurtrata RE HE Hr omg Raiha Magnet Shop Spuble motor Brermnsteffpumre DK 9560 Hadsund EL DIAGRAM NEPTUNE 7 66DE Rugg Jetwash Direct Itd NEPTUNE 7 66DE 3 OF 3 FRANCO Lontrb aur Blech gechmpnus Capteur de tenperature Indiceteur de debt 1 Lange Pedut d sauindcateur dg 2 Interrupteur Conpteur Berctrangue Capteur de tanne Sutomate combustible Swich dhule Deier tenperateur moteur Candensateur Fusdbis fil fin fil fin fil fin B nirat Mir Binirat Mur 221 Paar du dararruur hter da m lar Motgur danarage Interrupreur Trans
40. flap with varnish Fuel pressure setting Air flap eMount pressure gauge on the fuel pump e The air flap on the side of the burner fan is eAdjust the fuel pressure according to the adjusted by a self locking spindle on a set values in Technical data chapter A screw Turning clockwise increases the air intake turning counterclockwise reduces it NEPTUNE PE DE en Ver 1 0 October 2010 69 Jetwash Direct Itd Adjustment Test Burner settings Fig G 17 Soot raiting Determine the soot rating with a soot pump 1 and soot rating reference scale The figure should not exceed 1 Otherwise open the air flap Fig G 07 a little and repeat the measure ment Repeat the procedure until the specified value is obtained Service time setting gt Fig G 18 Burner measurements The CO2 content in the exhaust the intake and exhaust temperature are determined This can be done with conventional meters or as in Fig G 08 with an electronic meter like the TESTO 325 4 which measures and displays all relevant data If the measured value is too low close the air flap Fig G 06 a little and check the soot rating and Co2 content again BR2 X5 For Datalogger and Service Interval Fuel LED Antistone LED Service LED Pump Oil LED Operation LED Switch off machine with 51 install a jumper on X5 between pin 3 and 5 Switch on machine cold water mode
41. k through the safety valve into the high pressure pump the thermal release responds and shuts down the entire machine through the control circuit Be fore restarting the machine must cool down the fault causing the heated water to flow in the wrong direction must be corrected and a new thermal release fitted The flame sensor is a light sensitive phototransistor The flame sensor checks for the presence of a flame NEPTUNE PE DE en Ver 1 0 October 2010 37 Jetwash Direct Itd Troubleshooting D __ __ __ ___ __ __ Green LED illumi v nates Yellow illumi nates Yellow _ flas hes ANTI STONE Red LED illumina tes Hed LED flashes Hed LED illumina tes NEPTUNE PE DE en Ver 1 0 Octo Machine ready to opeate All LEDs flash once be fore the motor is turned on Fuel level is low Alto Anti Stone level is low Pump oil level is low Service interval service due in 20 hours Service interval elapsed Jetwash Direc Refill fuel Cold water mode is possible Refill Alto Anti Stone Hot water and Cold water mode is possible Refill pump oil Chapter F 1 3 The burner and motor are cut out The green LED extinguis hes Service the machine Hot water and Cold water mode is possible Service the machine Hot water and Cold water mode is possible 38 Troubleshooting D Fault Green LED flas hes v
42. le Close the detergent dos ing valve the spray pipe off the spray pistol Operate the spray pistol and let the ma chine run until the air is expelled from the sys tem and the pump works smoothly 41 ALTO service Repair NA5 Pump NEPTUNE PE DE en Ver 1 0 October 2010 42 Jetwash Direct Itd ALTO service Repair NA5 Pump Valves Fig F 13 Valve housing Fig F 14 Thrust collar Dismount the valve housing from the Be carefull not to damage the surface cylinder block by the three M12 bolts inside when dismounting the thrust collar Be aware of the o rings and valve parts Inspect the thrust collar for damages before mounting Fig F 15 Valve housing Fig F 16 Valve housing Carefully tip out the sleeves with an Knock carefully on the back side of the adequate screwdriver and replace them Be valve seat to demount it or use an 8mm careful not to scratch the surface threaded pin and pull it out Replace with new parts NEPTUNE PE DE en Ver 1 0 October 2010 43 Jetwash Direct Itd ALTO service Repair NA5 Pump Valves Pic F 17 Suction valves Pic F 18 Pressure valves Overview of the placement of suction valve Overview of the placement of pressure parts valve parts Fig F 19 Pressure valves Fig F 20 Pressure valve seat The pressure valves can easily be taken Take out the pressure valve seats with out of the cylinder head a
43. level etc 10642212 Ge A ver of 3 On the above picture is the correct setting of the circuit board Arrow 1 Setting is WITHOUT JUMPER By pass time active Arrow 2 Setting is JUMPER MOUNTED ON PIN 2 AND 3 Flame Sensor active 27 Jetwash Direct Itd Nilfisk ALTO Function D NEPTUNE PE DE NP5 PUMP The 3piston radial pump 5 is used in the NEPTUNE 5 85PE and 5 51DE Cam shaft Pressure valve Suction valve The three pistons are driven by the motor via a belt drive The cam shaft transforms the rotation power into the pistons reciprocating movements The movement and the diameter of the pistons decide the water volume which can be sucked into the suction valves and pressed out through the pressure valves NEPTUNE PE DE en Ver 1 0 October 2010 28 Jetwash Direct Itd Nilfisk ALTO Function NEPTUNE PE DE NA5 PUMP 3piston NA5 pump is used in the NEPTUNE 5 46PE and 5 54PE Oy 1 Ka we 7 2 v oS S Honda motor and D bearing cover 25 Orso Q oe Pistons cylinder block cylinder head and sealings 00 1 199 T 3 Water inlet 15 By pass valve with water re gulator Qo qm 0 5 225 The NA5 pump is connected the Honda motor with a direct drive By pass valve function is described later in this service manual NEPTUNE PE DE en Ver 1 0 October 2010 29 Jetwash Direct It
44. n adequate puller or use an 8mm Replace with new parts if necessary threaded pin Replace with new parts if necessary NEPTUNE PE DE en Ver 1 0 October 2010 44 Jetwash Direct Itd ALTO service Repair NA5 Pump Cylinder Block Fig F 21 Cylinder block Fig F 22 Oil Sleeves Overview of the placement of the parts in Take out the oil sleeves using an the cylinder block adequate screwdriver Be careful not to damage the surface of the cylinder block Oil seal and piston Fig F 23 Valve Kit 3 Exploded View Fig F 24 Pistons To make replacement easier moisten the Place sleeves pistons and springs as sleeves with soapy water shown Mount the sleeves using a 19mm box Mount the cylinder block to the D bearing spanner and a fiber hammer cover by the two 6mm mounting screws NEPTUNE PE DE en 1 0 October 2010 45 Jetwash Direct Itd ALTO service Repair Wobble disc pomme Hee Fig F 25 Pump head The cylinder head and the cylinder block is fastend to the D bearing cover by two 6mm mounting bolts for the cylinder block and three 12mm bolts for the cylinder head Fig F 27 Wobble disc The center bolt is fixing the wobble disc to the motor shaft and ensure the rotor to be kept in the right position in proportion to the stator NEPTUNE PE DE en Ver 1 0 October 2010 NA5 Pump Fig F 26 D bearing cover and wobble disc
45. nance plan C3 and Na5 NP 5 pump only pump everysix AS Y operating hours 500 operating hours Water filters Q Oil filter Q Checking the pump oil quality Q Changing the pump oil Q Q Emptying the fuel oil tank Q NEPTUNE PE DE en Ver 1 0 October 2010 62 Jetwash Direct Itd Adjustment Test IMPORTANT When torque settings are made all parts Pump screws etc must have a temperature at 20 C NA5 pump Torque specifications i a m 1 e i A 5 N N Fig G 02 Cylinder block Fig G 04 Venting valve 10 Nm By hand 40 Nm 40 Nm Fig G 07 Outlet fittings Fig G 08 Water regulation NEPTUNE PE DE en Ver 1 0 October 2010 63 Jetwash Direct Itd WER Adjustment Test NA5 pump Adjustment of by pass system Fig G 09 Pressure gauge Fig G 10 Test tap Dismount the test plug in the by pass housing Connect a test tap A hose and pressure and mount a pressure gauge instead gun to the outlet of the machine Fig G 11 Safety valve Fig G 12 Pressure bolt Close the safety valve completely Adjust the test tap A and the pressure bolt B so it couples 20 30 bars higher than working pressure when the pressure gun is closed CUT OFF PRESSURE After the cut off pressure is reached the machine runs in by pass untill the pressure gun is opened The working pressure 15 stated in the tech nical data sheets chap
46. nter will count no matter if the motor is running or not NEPTUNE PE DE en Ver 1 0 October 2010 18 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of NEPTUNE 5 46PE 5 54PE and 7 61PE CH 14 3 30 3 28 a uai lim 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 NEPTUNE PE DE en Ver 1 0 October 2010 19 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of NEPTUNE 5 51DE Charging Generaber Brown k Start Relay Battery 12V Regulator R55 117 4 2 IT IBI e ei a AAA Hmm 1 2 peel 1 pol coupler 10 gt 106422125 ver 1073 Start the motor by shortly turning the key 5 into the start position When
47. ool Work without an exten sion cable or use an ex tension cable with a lar ger cross section Possibly a phase failure have the electrical con nection checked Correct the cause of the fault Chapter D 2 3 5 and replace the thermal release Chapter F 7 4 Correct the cause of the fault and replace the fine wire fuse Chapter F 8 1 oee Chapter F 2 6 and F 7 Cold water mode is possible If this option is fitted re move it and clean it NEPTUNE PE DE en Ver 1 0 October 2010 40 Jetwash Direct Itd Troubleshooting D EL E Green LED does not illuminate Pressure too low Machine runs jerk ily NEPTUNE PE DE en Ver 1 0 October 2010 No power to microproc e HP nozzle worn Pressure rate control or Vario Press set for too low a pressure Flexo Power nozzle open HP pump taking air in from empty detergent tank Jetwash Direct Itd Make sure the machine is plugged in Operate main switch 51 Check the primary and secondary voltage 8 Vac on transformer 1 Pico fuse 1 has blown self resetting Wait un til F1 is reset or if the fault persists replace electronic controller A1 Chapter F 8 1 Heplace the HP nozzle Turn the pressure rate control on the unloader valve in the direction or set the Vario Press rotary knob accessory on the pistol for a larger amount of water Close the Flexo Power nozz
48. ors 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 NEPTUNE PE DE en Ver 1 0 October 2010 4 Jetwash Direct Itd Safety instructions For your own safety 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 Before using the cleaner al be allowed to use the cleaner ways read the operating instructions and keep them readily available Repair work should be carried out by persons instructed and trained in repairing this product NEPTUNE PE DE en Ver 1 0 October 2010 5 Jetwash Direct Itd Technical data NEPTUNE PE 42 Power HK RPM 9 5 3600 11 0 3600 CCM Cm3 337 389 Motor RPM adjusted RPM 3550 3400 Motor oil type SAE 15 40 SAE 15 40 188 Water Quantity high pressure l min meter Pump pressure bar 198 13 5 Suction capacity feede
49. p spol jl input NEPTUNE PE DE en Ver 1 0 October 2010 54 T EaLISH Flarcirunr cantroler LEO board Control bax 5er Aawealtch 1 wrana 2 Pump dl Level Tus Motor ol seth Therma sateh mn Capa Pechhfier Fuge cen rad en Fusa Fuse LED Ward 12 DL Generator Battery col Hator Iani Motor fan Matar Inrarti Frars nrmar ignition Fremarner Terminal strip Plug valve Chop froto Errer Input Nilfisk ALTO DEUTLH hFuuralaktranik LED Keniral sensor arr nunpsu amp tter 1 Tharrsnclrharuru 2 Pnp acha l ee sode Orennetett MaFurH echalter Toun Kordensetar lekhrichr Falnsicherung Platina Funsihgrung kantrol Funsihgrung Platinal BY 0 Generator Gu eri 2 Farar Matar Shaurtrata clrdtrate enn Pek he Magrer venti mater Feber Input DK 9560 Hodsund EL DIAGRAM NEPTUNE 5 5BPE Honda Zcyl Jetwash Direct Itd NEPTUNE 5 85PE 3 OF 3 Lontr eur kereng LEO Kerenge Waite romane Capteur de
50. perature sensor water outlet Flow switch 1 and 2 NEPTUNE PE DE en Ver 1 0 October 2010 16 Jetwash Direct Itd Construction 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 A small special hexagon key for easy adjustment of the fuel pressu re is placed in the electric box in all NEPTUNE PE Fuel pump access DE machines through the square hole on the right side of the fuel tank Mitsubishi motor Oil container w level sensor Temperature By pass valve pump sensor pump WI water regu Temperature sensor lator exhaust Temperature sensor water outlet Flow switch 1 and 2 NEPTUNE PE DE en Ver 1 0 October 2010 17 Jetwash Direct Itd Nilfisk ALTO Function D Functional desription of NEPTUNE 5 46PE 5 54PE and 7 61 202 2227 777 T 1 Nilfisk E mme ALTO EL DIAGRAM 106122197 NEPTUNE 5 46PE 8 1013 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 ONT 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 cou
51. pressure When the correct pressure is ad justed tighten the lock nut with a 13 mm Box Spanner NEPTUNE PE DE en Ver 1 0 October 2010 68 Jetwash Direct Itd Adjustment Test Burner settings Note Higher CO2 concentrations at different barometric pressure altitude or temperature and poor quality of the used fuel can lead to faster soot deposition on the heating coil of the heat exchanger Preparation 1 Set the fuel pressure 2 Let the machine run in Hot water mode for at least two minutes so that it reaches operating temperature and meaningful results can be measured Note Machines that are primarily used for a brief period should run continuously for about half an hour in Hot water mode before an exhaust measurement Measurement 3 Determine the soot rating with a soot pump and soot rating reference scale The figure should not exceed 1 Otherwise open the air flap a little and repeat the measurement Repeat the procedure until the specified value is obtained 4 Then the CO2 content in the exhaust the intake and exhaust temperature are determined This can be done with conventional meters or with an electronic meter like the TESTO 325 which measures and displays all relevant data If the measured value is too low close the air flap a little and check the soot rating and Co2 content again Repeat all settings until all soecified values are obtained 5 Finally seal the set screw arrow A of the air
52. re is pulled and runs the starter motor and the motor will start Now release the key so it goes back to the ON position the starter coil Y2 red wire is no longer pulled but the holding coil Y2 white wire is kept hold through the contactor K3 If there is a failure on B5 oil level switch pump oil B10 Motor oil switch B11 thermo switch mo tor or B12 thermo switch high pressure pump output 15 on A2 is connected to ground contactor K3 opens and the holding coil Y2 opens and the motor stops It is important that the jumper is mounted on the circuit board A2 When jumper mounted there is 12VDC on output 7 on A2 Output 7 is connected to connection R on the generator The generator G1 can only give output if there is 12VDC present on connection If the generator is worn defect the DC voltage on connection L drops down to 0 VDC and input 6 on A2 in then connected to ground and the charging LED will light up NEPTUNE PE DE en Ver 1 0 October 2010 22 Jetwash Direct Itd Nilfisk ALTO Function Functional desription of NEPTUNE 5 85PE Black Y Yella a Gree zt Combination switch 1 Nilfisk d ci ALTO DK 9560 Hadsund Br Brown f Orange __ FL DIAGRAM 406122122 Lb Light blue Lj Li green alll Zeen Je Sg toto NEPTUNE 5 85PE Honda 2cyl If there is a failure on B5 oil level switch pump oil B10 motor oil switch or B12
53. stops spray handle is released closed the pressure drop over piston disap pears the pressure in the by pass valve increases briefly until the safety valve F opens The safety valve just opens briefly and closes again The safety valve opens when the pump pressure overcomes the tension of the spring in the safety valve The safety valve is adjusted to open 25 30 bar above normal working pressure Now the valve cone D lift from its seat and water runs in by pass 33 Jetwash Direct Itd Nilfisk ALTO Function D Unloader valve function NEPTUNE 5 85Pe AND 5 51DE Unloader disassembled NEPTUNE PE DE en Ver 1 0 October 2010 Unloader function On the assumption that the black handle adjustment handle on the unloader is turned all the way to max pressure clockwise When the pump is running the unloader piston 2 is pressed down it its seat 1 and all the water volume is going through the gun and out to the high pressure nozzle When the gun is released no water flow out the pressure in the unloader will rise and the in creased pressure will overcome the adjusted ten sion of the unloader spring 6 and the unloader piston 2 will be lifted up from its seat Water will now return through the seat 1 to the suction side of the pump by pass mode 34 Jetwash Direct Itd ALTO Function Flow switch function NEPTUNE PE Reed Switch E
54. temperature Indratgur de dob 1 Lampe iim FeduF d esuindicetewr de deht 2 Interrupteur Capteur de Automgte fleHeur combustible mula Deter tenperateur onde mater Peed PERE Tl Tin age FusH fll sil de cormandel fll direananda wur Banaratuur 23 Allumaga Moteur dg went later de biler Molar ddnarragu TrensFormal uer TrensFomotes dallag Baret te de raccordenent Terminal ombus lertravanme Intruta paur ratuur entree Eretatning far 106427177 ver A 3073 83 Juan 4015 5 aun 0 19 SI NEPTUNE 5 51DE 1 OF 3 jire 1nd IZ AR d iring ell 55H 1 EE wor e apeg delt x e weu Nilfisk ALTO 84 Jetwash Direct Itd NEPTUNE PE DE en Ver 1 0 October 2010 x E O E Nilfisk ALTO NEPTUNE 5 51DE 2 OF 3 1015 5 3 193 WHYHOVIC IJ gt mn OLTE nM EI Ju 454 08000 405425 aju l2o F 2 Uadurl
55. ter B NEPTUNE PE DE en Ver 1 0 October 2010 64 Jetwash Direct Itd WER Adjustment Test NA5 pump Adjustment of by pass system Pressure bolt Safety valve When adjustment is done lock the bolt with Then let the machine run just below the cut the counter nut off pressure working adjustment and ad just the safety valve out until it couples out go into bypass Then you adjust the ad justing screw a 1 2 turn back and lock it with the counter nut Finalize the adjustment with locking glue paint on both the bolt and the safety valve NEPTUNE PE DE en Ver 1 0 October 2010 65 Jetwash Direct Itd WER Adjustment Test C3 pump Adjustment of by pass system Pos 1 Safety valve adjustment Pos 2 Set screw for min Water adjustment Pos 3 Min Water adjustment screw Minimum water volume and pressure adjustment First mount test manometer with correct high pressure test nozzle Turn the black handle on the water regulator all the way clockwise Min Water volume Start the motor and run at full RPM Test manometer must show approx 30 bar If this is not the case loosen set screw pos 2 and then turn the min Water adjustment screw pos 3 untill you reach approx 30 bar Safety valve adjustment First mount test manometer without test nozzle just open outlet Turn the black handle on the water regulator all the way counterclockwise Max Water vol ume Start the motor and run at
56. trength thread locker on each plunger rod when reinstalling plunger nut and torque to specifications Oil seals must be changed if there any signs of leaks or if they are removed The recommended way to remove the oil seals which are pressed into the pump body is to sew the seal with an awl and pry down When installing new seals a light coating of lubricant on the seals may ease the installation Make sure it is pressed in using equal pressure around the entire circumference NEPTUNE PE DE en Ver 1 0 October 2010 57 Jetwash Direct Itd Service Repair Imp NP5 Unloader valve NP5 Unloader valve NP5 Unloader valve parts NEPTUNE PE DE en Ver 1 0 October 2010 58 Jetwash Direct Itd ALTO Service Repair Boiler The boiler is the heat generating part of a hot water machine It consists of a labyrinth constructed tube coil which encloses the combustion chamber The tube coil is enclosed by a double container with boiler jacket bottom and top in a sandwich construction between which the combustion air is routed into the combustion An insulating material placed in the bottom of the boiler makes sure that the inner bottom among other things is protected from superheating Flame sensor Electrodes Fuel nozzle Exhaust Water outlet Water inlet Top plate Air distributor Flame tube top part Burner tube Flame tube Fixation spacer Outer jacket Inner jacket Air inlet
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