Service Manual
Contents
1. 43018 TAINH dund dund 110 Juin yue Jal ID 5 HOMO ayi JI Jau ng fejau Play 1418197 WINS way arte tie ez la ni 21 ZEN ung 11 Jy 9005 RE inre pres 19 5 28 awe LB l DANS d ta Ali E NAE t B uL ins w l H dd a dd QUO 318 281 8431 BUDS uy dung jen UO Blade gh gh gh gh gh qn ee ee OF Ed E i 9 N I al m A m Lt LV 58 NEPTUNE 5 FA EN 2 0 25 11 iagrams d ALTO iring EE F mz roads iusso 5 pabueup ep pug 20 a Buona San gadumiejo jon 5 00 6502 18 asa pmanamen i 2190 25 Y4 21442313 L 40 Gy e 0 TEL s LL WHIMS dund aje3syuy EL dund LA J3un uo qas zl LI2. CO2contntmin 105 05 00 105 05 00 Efficiencybumer 920 15 05 925 15105 Boop Exhaust outlet temperature 1600 100100 1750 1001100 Evhaust temperature cut of CC 2700 00 i20 200 09 120 dT 45 an __ 39 A48 es 12 C inlet 6 7 48 48 e in coil 1 Fueltank D tt oen Gun SrERGO200 STERGO2000 Lace TORNADOPLUS TORNADOPLUS Hoe O DN8x20m38 8 20 3 8 High Pressure Nozzle NT050 Noise level 1m Lpa dBA 764 15 15 800 15 15 Noisepower LWA dB A 920 15 15 940 15 15 Impactforce no 470 Vibration ISO 5349 ms 25 25 Protection Class O O IPX PX detergent flow 4 0 from full internal tank 96 1 0 1 0 1 0 1 0 Max detergent flow 05 from full internal tank L min 0 2 0 2 0 7 0 2 10 2 lt Z Z IT T L NEPTUNE 5 FA EN Ver 2 0 25 11 16 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Pump Data Max inlet pressure ban 100 100 Inlet temperature 400 400 Pressureatpumphead 0 190 10 10 195
3. LA LA Display black 7 ai blach 7 y y y Q black E blach Fuel Pumpoil Service Anti shone yBllpu green DO yellow green Ali ALTO pa pe a one T Cremted wa Electric diagram M Iph 1 164 US Drawing number e 108270540 Mat apatifis tolerances q Hes occording kn Haw terminal black HPC 2609 166 aa ES M NEPTUNE 5 FA EN 2 0 25 11 adia 15 2142911 iagrams d iring yd E EIN ADD al ETL Ud fed UAT PO ILE JEU A I I I dard ipse d T Id 1045 mee Nilfisk ALTO Why Compromise 55 NEPTUNE 5 FA EN 2 0 25 11 iagrams d ALTO iring Py 94 qpuseiq 5082 e see autos LELELZ 9901 TUDES ISLIP ydg Y4 21442213 roads AS 0 6008 29 zm Buipuoooo aH zg ssl 4
4. 991 4002 IdH vou wea O Bam om eased nan pH BOULE ana BO DL 3 amp 1 l x epe uaaJl raajat C CS uas imn sa ego nh zn m G 0 Il 5 L pey AJOU Td dud 31g 25 Jug EA E dwad 10 LA vayounp LL Jaw J0 JUE 11 LIDITIUB tL SWE 1 240 40 1 JD Jojlajoud lH ueg Jaung EM 22400 LW 9514 LI3 23 13 Jan JED d sunt WUE L31185 ba JWE L qo dud 5 jenjj 49 gapas dwa panes 1 dogs es AA 10 J sug5 paeog Aejdsip Jara ue 3194133 3 EI z H 3d 15 ug Cur eJadp Z gh gh gh gh ty oe 18 LV m Fr LB EX Jalibn e jen 56 NEPTUNE 5 EN Ver 2 0 25 11 BLLILI e we a HG sil 6Dbz Jdh H zm Buipuoooo Di B sg pue zg 33 691Z dH EHB Y4 ue Beip 21242813 rs ros ne unga sao n m ELLELE YADI Be epa AA may pa mung 80 MED ah gh gh gh gh B 8254 t 47219 82510 54219 E
5. DN8x20m38 NTO500 Noise level 1m Lpa dBA 1782 115 15 764 15 15 Noisepower LWA dB A 960 15 15 920 15 15 Impactforce N 560 420 180 8348 m o ES S WS o Protection Class O O PX f rue a from full internal tank 96 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 7 0 2 0 2 0 5 0 2 0 2 NEPTUNE 5 EN Ver 2 0 25 11 14 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Pump Data inlet pressure ban A 100 17 100 Inlet temperature E 900 _ Pressure atpumphead 1799 13 7 7 7 e bar 138 prese Pressure Outlet e MO BEEN 2 7 Pressure cut off T TLL Lla 250 0 pressure a valve E ree 0 rea 0 250 0 5 0 5 0 Dec _2 ole _ _03 0 3 Flow min 5 144 07077 169 08108 Tye NAS NAB Pistontype Ceme Piston diameter mm 200 20 Stroke Wobblediscange 94 I 102 aeee O _ Pump oil type Oil volume I Electrical Powersupply 200 3 6 2 230V 60Hz Current consump hot A 166 110 130 J 280 10 30 Current consump cold A
6. PT 4E f5 2 1345 1 jar LM L ch Jaap JOLIE 1147 mar I Eny ms ga xdi uas YIJIMS Len ag an JOSUE AWE La lab Eb dwad yayims 42014 gg dua psneyxy 1 days Lug 5 H 114 JOSUAS aJnjeJadwaj ig pJeoq amp g dsiz i 31 0 12415 Lv 3d 1 11 due s jug as JE dung 1819 gh gh gh yh LETT ian ______ DO fed sig 79 Sa EN 3x 1 58 Il 9 5 0 qn Il 5 5 5 LOA 5 55 1 ps EX X A5 Jalibn e Je LlI 50 05 1 6 m ak r Lv 59 NEPTUNE 5 EN Ver 2 0 25 11 60 O puj MT rend pf seo dund T rca s G s n RE jou nue EM 2790 mE EENI ud MI 003 JEUIWJA EX ZELK EIL EAE LCG 04 peysede x Ix asni ibd dild mp Ra ayo E 1 vj dys ua umi ueJbeip 314423 3 j m 66 9ejgpiod s Depniug suis E unindiacmnap H ID LI AB SID JDJIFUUOF grep IS 1 my
7. XP220 Oil volume I Electrical Power supply 400 230V 3 50Hz 220 440 3 60 2 Current consump hot A 158 25 10 30 125 218 10 30 Current consump cold A 16 25 110 30 127 22 10 30 Power Consumption hot kW 78 76 05 05 78 7 05 05 Fusesize A 29 46 __24 16 Cord type 7 HORN F4G25 60 HO7RN FAG25x6m Pugtpe Control 1 PCB24vol PCB2 volt Contactor 10 0 100050 Electrical diagram _________ 106427777477 106427177 1 Eletrical test data Highvoltage HV test V 100 1000Vac HV Resistance MO 21MQ 500Vac 21MQ 500Vdc Cord resistance Ohm ____ 2 2 Motor Data Motortype induction 3 Inducion Rotational speed min 1 1450 1450 Insulation po ProtectionClass 1115844 54 Nominal power kW 67 130 30 67 30 30 Cos 08 j NEPTUNE 5 FA EN Ver 2 0 25 11 11 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Unit uu MEE t Y i 12 C Delta temp variance at 50 set point at gun C xa sls inlet 12 sec 5 0 5 0 Steam temp t II
8. 175 110 30 268 10 30 Power Consumption hot _S f_1 08 05 ___89 _1 08 98 Fuse size A 200 0 30 0 me D Ls type 4x3 5x6m AWG10 3X9 0 ___ 6 A ore Contactor 100 C3024V 50 60H 100 C12KJ10 5 5kw Electrical diagram 106421554 106420540 TEES test E Highvoltage HV test V 100 7 4100Va HV Resistance MQ 2IMQ 500Vdc z1MO 50Vdc v anmi Motortype po po 3 Iductin St Induction Rotationalspeed min 1 1450 1450 Insulation ClassF Protection Class 15844 111584 Nominal power kw 40 13030 52 30 30 Co ______________________ o o o o OS 908 o NEPTUNE 5 FA EN Ver 2 0 25 11 15 Nilfisk ALTO Technical data Why Compromise Test result Tol Tol Test result Tol Tol 67 0 j 7804 78 2 00130 744 00 30 Delta temp variance at 50 C 30 0 set point at gun C 3 0 3 0 Boiler on time y 50 C set point inlet 12 sec 5 0 5 0 5 0 5 0 Steam temp t Il outlet and v 140 0 Steam nozzle 10 0 30 0 140 0 10 0 30 0 Pressure P2 per with 27 0 standard nozzle p 0 PEE 0 27 0 5 0 5 0 Fuel pump Fuel pump type 000 Diesel Diesel Nozzle size oil 1356vH 1756
9. DN 10x20m3 8 High Pressure Nozzle O Z4J Noise level 1m dBA 782 15 15 782 15 15 Noisepower LWA 960 15 15 960 15 15 forge Vibration ISO 5349 bration SO 8249 m m s lt 2 5 Protection Class Max detergent flow from full internal tank 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 2 0 2 0 2 0 2 NEPTUNE 5 FA EN Ver 2 0 25 11 18 Nilfisk ALTO Construction Neptune 5 Variants Single phase 5 50 US Three phase 5 44 JP 5 50 EU 5 61 EU 5 61NO 5 61 EXP 5 61 AU 5 FA SB X vs Standard Hose Reel and Hose lenght 15m on X models 1 These numbers refer to the theoretical total impact of spraying water calculated by the formula Impact Q1 x V P1x0 24 N P1 bar Q1 I min v P1 The Neptune 5 FA is build with a NA5 pump The by pass system is flow activated unlike the pressure activated by pass system known from previous Neptune machines The frame cabinet detergent tank and fuel tank is identical to previous Neptune 5 models Burner fan housing Anti scale pump Water break tank Anti scale tank oafety valve Fuel filter Electrodes Ignition transformer Boiler outlet with temperature sensor NEPTUNE 5 EN Ver 2 0 25 11 Fig C 1 Side view Boiler Fuel pump Flow control Pressure water regulation By pass valve Fuel gauge
10. p 3 ster tou 5 dois 2246 U24 5 v T3C HV 15 25 TEGETE 28 Jauo u3 I 5 5 1 5 LH JOJOU 1050 4D JULI ZH 4 4 1044097 Ly Uns a let 116 Hud rg uueJaug gh yh gh yh yh ABE x 5 O IS C E M M LA w Y D ug 2 Lu dd ET Z1 3l Jalibn g JE lt 3 10 Uum 9 2 B 8 lt n Si lt iagrams d ALTO iring mam _ m ESE mz fasubos Gaunildak j vaad NS _ EOL GG02 24H 81172190 ome P mauna PH Js 418 ps udi 74 21442913 09 6008 599 60040 opo kay x J mm J wendumen SWR m x ER Ex LES 679 Pa Usb 29 41219 1 41219 8 5 42810 7 E19 8 4284 30019 a ELTE eumd 5161 dund ja uni a3un Jat UIE 1319 Jn 3 1 Jaen 104384010 saung Jo ju 914 PALES
11. 140 Insulation 2 ClsF _ j gt 30 30 a 40 o o H NEPTUNESFA Ver20 25 11 FA Ver 2 0 25 11 13 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Heating Unit Boilerpower_input kW 850 60 Temperature t Qinlet 2C 408 00 30 775 00 30 set point at gun C 30 0 3 0 30 0 3 0 Boiler on time at 50 C set point so so inlet 12 sec 30 0 5 0 5 0 30 0 5 0 5 0 Steam nozzle C 140 0 10 0 30 0 140 0 10 0 30 0 Pressure P2 outlet with standard nozzle bar 27 0 5 0 5 0 27 0 5 0 5 0 Fuelpumptype 11 __ Diesel Oil pressure 771720 05100720 05 00 Nozzle size ol 17560 13560 H content min m An f DE M tn 09 Eficienoybumer de B20 _ 1505 920 15 05 Sootpicture oa Exhaust 150 1001050 1600 400 400 Exhaust temperature cut of e 5 aoo 2mo oo 0 Fuel consump dT 45 deg kg h 12 C inlet 7 3 5 7 Water volume in coil 212048 __ aren Gun 1 5 2000 STERGO200 Lace 71 TORNADOPLUS TORNADOPLUS Hoe j DN8x20m38 DN820m38 High Pressure Nozzle
12. Why Compromise Adjustment of by pass system Fig G 09 Pressure gauge Fig G 10 Test tap Connect test pressure gauge 1206358 to the Machines with hose reel machine water outlet Connect extension hose 301001311and test pressure gauge 1206358 to the machine water outlet Fig G 11 Safety valve Fig G 12 Pressure bolt Check the working pressure in data sheets Turn pressure bolt B Fig G12 1 to 2 turns chapter B out to ensure that a too high cut off pressure will not damage the by pass valve Close the safety valve completely Adjust the test tap A Fig G 09 amp G 10 and the pressure bolt B so it couples 20 30 bars higher than working pressure when the pres sure gun is closed CUT OFF PRESSURE After the cut off pressure is reached the ma chine runs in by pass untill the pressure gun is opened NEPTUNE 5 FA EN Ver 2 0 25 11 50 Nilfisk ALTO Why Compromise Adjustment Test Fig G 13 Pressure bolt When adjustment is done lock the bolt with the counter nut NOTE If the cut off pressure is adjusted too high 60 bar higher than working pressure the by pass valve can be damaged due to fast and hard movements during the change from working pressure to by pass pressure NEPTUNE 5 EN Ver 2 0 25 11 Fig G 14 Safety valve Let the machine run 5 bars lower than the cut off pressure working adjustment and adjust the safety valve out Counter clockwise until it couples out go int
13. must be mounted against the D bearing must be mounted against the bearings cover and the wobble disc NEPTUNE 5 FA EN Ver 2 0 25 11 44 Nilfisk ALTO Service Repair Why Compromise D bearing cover r Fig F 34 D bearing cover Fig F 35 Oil sleeve The D bearing cover is mounted to the The oil sleeve in the D bearing cover can Motor by four 6mm bolts be demounted carelully using a When the bearing is damaged always screwdriver replace the complete D bearing cover Mount the oil sleeve by using an adequate box spanner and a fiber hammer Electrical motor Fig F 36 Electrical Motor Fig F 37 fan Overview of the motor parts The fan can be demounted by taking off the lock ring and carelully push the fan with a screwdriver NEPTUNE 5 FA EN Ver 2 0 25 11 45 Nilfisk ALTO Service Repair Why Compromise Fuel tank Heating system Fig F 38 Fuel tank Overview 1 Detergent tank 2 Fuel tank 3 Strainer 4 Float valve 5 gasket Fig F 39 Heating system Overview 1 Ignition Transformer 4 Flame sensor 2 Ignition cords 5 Fuel nozzle 3 Ignition electrodes 6 Air distributer CENT Ld Fig F 40 Fuel nozzle Fig F 41 Fuel nozzle NEPTUNE 5 FA EN Ver 2 0 25 11 46 Nilfisk ALTO Service Repair Why Compromise Exhaust temperature sensor Fig F 42 Temperatur sensor Fig F 43 Temperatur relay e The exhaust tempera
14. 30 0 5 0 5 0 5 0 Steam temp t Il outlet and v Steam nozzle C 140 0 10 0 30 0 140 0 10 0 Pressure P2 outlet with standard nozzle bar 27 0 5 0 5 0 27 0 5 0 Fuelpumptype 1 Dist Oil pressure bar 12 05 00 120 05 00 Nozzesize ol 13560H 150 CO2contentmin 1 105 05 00 105 05 00 Efficiency burner 1 920 71505 920 15 05 rra 0 1 us NEN Exhaust outlet temperature CC 71600 1001400 1750 100100 2mo taal xm io Fuel consump 6847 45 destra 35 per s 2 12 C inlet D 7 3 Water volume in coil 1 I Others Gn STERGO200 STERGO2000 Lance TORNADOPLUS TORNADOPLUS 3 JDN 8xf0mQuick3 8 DN 8 10 Quick 3 8 High Pressure Nozzle 700 550 Noise level 1m Mi a 764 15115 782 11515 Noisepower LWA dB A oao 11515 960 15 15 Impactforce 260 585380 Vibration ISO 5349 ms 25 ECCE E Class Protection Class IPX5 PX IP X5 Max detergent flow from full internal tank 96 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 5 0 2 0 2 0 2 0 2 NEPTUNE 5 FA EN Ver 2 0 25 11 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test r
15. Boiler inlet Flame sensor Fuel nozzle Exhaust thermal safety sensor 19 Nilfisk ALTO Construction Fig C 3 Frame amp cabinet parts 1 Lance holder 7 Handle 2 Detergent tank 8 Detergent tank 3 Fuel tank 9 Water break tank 4 Fuel filter 10 External detergent filter 5 cover 11 Frame 6 Side cabinet right 12 Side cabinet left NEPTUNE 5 EN Ver 2 0 25 11 20 Nilfisk _ ALIO Construction Why Compromise The electric box Fig C 6 contains the control board the transformer relays fuses and connection terminals The cover plate is mounted with the main switch the display the temperature adjustment and five status warningLights Fig C 4 The cover is sealed around the edge and around the manometer and the detergent valve P Main switch S1 Display OFF COLD HOT Temperature setting Error mesage L Running hours Adjustment Sevice interval setting Temperature settings Service interval settings Pressure Gauqe g Anti stone Detergent Service A B Fig C 5 Panel inside Control board A1 Ignition transformer 11 Fuse F11 Contactor K1 Fig C 6 Electrical box NEPTUNE 5 EN Ver 2 0 25 11 21 Nilfisk ALTO Construction The electric control system is built up around the control board 1 which is divided into two 5 stems a 5V DC system on one side to supply the sensors B8 B4 B6 B1 B9 B7 and on the other s
16. ClasF ProtectionClass O IP54 54 Nominalpower KW 55 30130 55 30 30 Cosj 07 07 NEPTUNE 5 FA Ver 2 0 25 11 5 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol m Unit mo 7 loo eC Temperature tmax inlet12 C 877 00130 87 00 50 uim e FPN set point at gun C 3 0 3 0 xus vem we mo inlet 12 sec 5 0 5 0 seem maja Steam nozzle 140 0 10 0 30 0 140 0 10 0 30 0 standard nozzle bar 27 0 5 0 5 0 27 0 5 0 5 0 Fuel pump type Diesel Diesel pressure bar 1600 05 00 100 05 00 Nozzle size oil 1756 A7560H CO2 content min 105 05100 105 05 00 Efficiency burner 920 15105 920 15 05 Soot picture O owa a J Exhaust outlet temperature C 1750 100 100 1750 100 100 temperature eo 200 00 201 200 00 120 Fuel consump dT 45 deg kgh 40 imi kg h 12 C inlet e n E Water volume in coil l DEMNM Others Gun STERGO200 5 2000 Lance TORNADOPLUS Hose DN8xXi om 3 8 DN8xOM High Pr
17. D Dung gk og v TT Jabb ye yen EA 14 ul IL 5 LM 157371 agde 23213 any jen ba 2914 2 J05UaS 10 dund 18013 UH yijms dua jsneux3 1 Las d 5146815 9 JOJEJIBLI AD J i Jis Lid an jejadwa dejal BLiLLIB amp Ev pear ATSIC TY 001041 902 2100442913 Ly ugue adr 19 LS id pa L ji ig gd 61 NEPTUNE 5 EN Ver 2 0 25 11 Nilfisk ALTO Notes NEPTUNE 5 FA EN Ver 2 0 25 11 62 Nilfisk ALTO Why Compromise NEPTUNE 5 FA EN Ver 2 0 25 11 63
18. FA EN Ver 2 0 25 11 oafety instructions Repair work should be carried out by persons instructed in electrical installations or by trained electricians only Observe valid safety regulations for electrical equipment In particular observe the following regulations IEC 60335 2 79 EN 60335 2 79 Additionally Also see national regulations Before using the cleaner always read the operating instructions and keep them readily available Only allow the high pressure cleaner to be used by persons who have been trained in its use and who have been explicitly authorized to use it Take the following ESD precautions before carrying out any repairs to the electronics e Touch the earth conductor before repairing the cleaner to discharge electrostatic charge from your body e Wear wrist band if necassary e Use a conductive floor covering or a conductive table cover e Never touch the printed circuit board or electronic components always hold on to plastic e Transport electronic components in conductive packaging e g ESD bag Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Pump Data inlet pressure ban 700 100 Inlet temperature C 400 fJ 400 Pressure atpumphead 0 175 10 10 71040 710 10 Pressure Cylinder Head bar 0 40 71010 185 710 10 Pr
19. Flow failure Flow sensor open while motor is running Flow problem or less water Leakage detect by micro sw flow sens Leakage Safety temperature switch open Hot safety temp switch Pumpoil switch open LED indication Pump oil error Light indication burner with fuel disabled Light fuel not activated No light indication burner with fuel enabled No light fuel enabled Fuel level switch open LED indication Fuel empty Thermal protector motor open Hot motor protector NEPTUNE 5 EN Ver 2 0 25 11 33 Nilfisk ALTO Troubleshooting Why Compromise ERROR CODE CHECK LIST Hot Safety temperature switch B3 opens when Wire defective cae 3 S due in boiler Boi be changed IF alid ler clogged up open Pump Oil Low Wire defective Oil seals worn out B6 Switch Switch B6 open Light sensor B7 see Light when Y1 is not activated Sensor in Flame sensor short circuit place Cold water operation not Wire defective possible Flow and pressure Boiler security switch out of ad adjustment justment Oil resi Switch must Oil residue in boi Oil pressure ler is burning Nozzle Y1 Leaky Electrode Egnition failure Flame sensor Pump pressure Hot Motor Protector too high Fan on motor de Motor winding 160degC room ffective 320degF gt 40degC Fuse F1 2amp 104degF Sensor in wi
20. Inside the Electrical Box e Replace if necessary Oil Maintenance Fuel filter Fig F 03 Oil extention Fig F 04 Fuel filter e Check the pump oil quality and quantity e Check the fuel filter and replace if necessary Refill if necessary e Change the oil at major repairs e Type of oil refer to part B NEPTUNE 5 FA EN Ver 2 0 25 11 36 Nilfisk ALTO Why Compromise Service Repair Electrical System Maintenance Fig F 05 Electrical box e Caution Before any repair on the electrical system Pull out the power plug e Remove the cover by loosing the 7 screws shown in the red circles e Caution On 1 machines capacitor might still be charged Fig F 06 E box knob disassembly e Loosen the screw in the bottom of the knob e Drag the knob out from the shaft e Note When closing the electrical box leave the wiring diagram inside Fig F 07 Electrical box Exploded view The components in the E box are shown by numbers in the wiring diagrams chapter H NEPTUNE 5 EN Ver 2 0 25 11 Fig F 08 Electrical box Back side Before connecting devices with voltage changeover Check that the pre selected voltage on the machine corresponds with the voltage of the electrical installation Otherwise the electrical devices of the machine can be destroyed 37 Nilfisk ALTO Service Repair Why Compromise By pass system Fig F 10 By pass valve cone By reassembling
21. Li Pu fa E al LI Pa a A L P ala 4 p n p s hg __ tar L us E ooo 2 ___ m 7 m 5 mani roa E a dis Insolation NEPTUNE 5 EN Ver 2 0 25 11 23 Nilfisk ALTO Construction Why Compromise 55306 X Q qoe o Pes Es m i ss fs Xoeeds OOO 6 99x SEA 9 u eme LA yo iet Fig C 9 Motor Pump unit The NA 5 three piston axial pump used in Neptune 5 FA is build in line with the electrical motor as one compact unit TO DAL 3 ex 12 2 CD E S g o e i S CD 9 224 Fig C 10 valve Fig C 11 Flow control The start stop system in Neptune 5 FA is flow The flow control checks if there is flow in the Activated system to stop and start the machine NEPTUNE 5 FA EN Ver 2 0 25 11 24 Nilfisk ALTO Function Why Compromise If the machine and the power supply are working correctly the following will happend during start up Display Suction from pump 58 A Hr 4 Status indicators Detergent valve A B Connected to water tank Fig D 1 Display Depending on the electronic set up the following will happen When the start switch is turned into cold water mode the display will show the running hours the ma chine has been used in cold and hot mode but it doesn
22. NEPTUNE 5 EN Ver 2 0 25 11 26 Nilfisk ALTO Function Why Compromise Fig D 3 Sensors amp actors Sensors B1 Temperature sensor in the outlet from the boiler Controls the combustion Y1 on off according to setting B2 Flow switch sense the flow out of the pump into the boiler and controls solenoid Y1 on off B3 Safety thermal switch placed in the exhaust of the machine if temperature 270 deg C 222 deg F will switch off if the burner keeps burning without water flow through the boiler B4 Flow switch controls the motor start stop When pressure is higher than working pressure the switch will open and the motor stops B6 Oil level sensor stops the machine if the pump is low on oil Activates red light on panel B7 Flame sensor detects light from the flame If the flame is not detected when it should be there the machine will be stopped B8 Level switch Anti Stone liquid If low yellow light will light up B9 Level switch fuel stops the fuel valve when low on fuel and yellow light appears on the panel MT Temperature switch stops the motor if the temperature in the windings is gt 160 deg 320 deg F Automatic reset Actors Y1 Solenoid opens closes the fuel for the burner T2 Ignition transformer is on when burner fan is running The machine is supplied with main power which is transformed into 8V AC to supply the micropro cessor and sensors and 24VAC to supply the actors contactor relay solen
23. ann 47219 iagrams O a B 42018 7 d m Bu x an EI A 5 95 d ig dund LA AN Sa upd ue piunt LI 5 Ho zl Lo _ _ i 1 E 15 TA gg LW LW ate i SIX Tan unas 58 1 HX3 CX uns ue 1581 a i i ye dwnd Jes d is durs seu 1 3 SI TX T EK ijs B Y I pas 77 lt 3119411313 Lv 4 Ban and LL Id 7045 0 Jabboyeyeq 4 2 1 q gt lt gt 57 NEPTUNE 5 EN Ver 2 0 25 11 iagrams d ALTO iring qpusaig soe pf seo fa az c gun ra 5 1 SS 3L zm SH TH gg yrs 3 o amf SENED an UOXITy ydi Y4 EL 212813 ws pnma unndiacmn Wiz maman 701 uas i nal B 19 L 8 qe b 1 4
24. count standby time 7 second later the motor will start building up pressure to cut off pressure and then by pass 20 second later the motor stops the display shows the set point of the temperature in degC or degF The indicator lights up the green light on the plug icon only The manometer shows by pass pressu re Now the machine is on stand by in cold water mode By switching to hot water mode the machine is then in stand by in hot water mode When the spray handle is activated flow will activate the flow switch and start the motor pump unit At the same time anti scale pump starts up and the fan for the burner starts ventilating the com bustion chamber for 3 sec before the fuel is pumped into the boiler and the combustion takes place The temperature will now raise until the setpoint has been reached The combustion will stop but the water temperature will climb a little higher before it gets down to the setpoint In the meantime the fan and the ignition are still working When the combustion starts at the setpoint the temperatu re will go a little lower before it starts rising The detergent valve makes it possible to choose between detergent A from the built in tank or deter gent B from the canister With the valve in off position as shown it draws in water from the tank to clean the channels NEPTUNE 5 EN Ver 2 0 25 11 25 Nilfisk ALTO Function When the machine is running in hot water mode the fan draws in air an
25. distributor Flame tube top part Flame tube Fig C 8 Boiler Burner tube Fixation spacer Outer jacket Inner jacket ERE LI Mounting plate e a filu A u m 1 da 1 La LI LI a m an LI nl LI mm m 4 iia we e E bs LE Ti CE i a e f m car s a Er ales E s li i A IP IM pi rmm L mi LI LI E a AP n M po a b m e a m 94 m LES mL s P P TERRE a l a L L LS m m Ly ia T mm Li i n ry E 1 ul M 2d m m k E EP E PE um m 1 E P LI LI a E Pa M a 1 p i 3 P of a Yr E uu P D S P Ma gme NE m zi Pu n LI Pa E EL L 5 gt ni dum E EP R m Li Pay pi ore PE m 15 a s k A d ap p mn Y 1 s P 2 A LES
26. in Fahrenheit NB it s not possible to cancel by pass time when temp display is set on Fahrenheit Se Cancel by pass time 4 Factory setting without hour display Hour display setting Bridges 3 and 5 to change service interval With the temperature adjustment knob100 to 600 hours Change to hotwater mode to set new setting 53 54 51 Al cel Electronic centraller 52 Display board H1 ONE AJ Starting relay 5 17 Bi Un SENSO Y MACAT ON a B Start step switch EXH T Exhaust temp switch H Float switch pump ail BT Flame Sensor m Float switch anti stane switch d z cit Aun capacitor m LI Starting capad ter Fuse I ae Relay Motor M2 Burner fan motor T EH MT Thermal protector moter Fil Discharge resishar Bi 54 4 x6 51 Switch TI Transformer ugi T2 Ignition transtarmer 5 1 Junction paint zz vi 11 lump israle pum 3 le pump x I O I EE i B3 1 TERMINAL BLOCK d black 1 black 1 O on gp 5 black 2 DI blach l l a black 3 E black 3 M T C blach amp ve black amp a Display ab TAN CH black 5 BI black 5 Ag mis Hlarh E de Hlark
27. nja Pressure Cylinder Head bar 0 195 4111 20 11 11 Pressure Oust ba o ma HEEL SE Pressure Pressure Gun bar x Gun bar 108 10 E lt hh a lala Cylinder Head bar oman mo Cylinder Head 250 0 5 0 5 0 250 0 5 0 5 0 Flow Qmax mi 55 169 08 04 169 08 08 Tp NA5 NENNEN Peston type m ee Piston dames Pump oil type GR XP220 GR XP220 Electrical Power supply 400 3 50 40V3 50z Current consump hot 454 1030 158 10 30 Current consump cold A 760 10 30 160 10 3 0 Power Consumption hot kw 76 05 05 78 05 05 Fuse size 160 40 Cord type 15 HO7RN F 4615 Plug type CEE3P N G 16A CEE3P N G 16A Control 11 PCB2vot PCB2vo Contactor 100 C16KJ1024 100 C16KJ1024 Electrical diagram 106427171 po 06427171 1 test E Highvoltage HV test 1000Vac 1000 HV Resistance 21MQ 500Vdc gt 1 0 500 Con Ohm ____ 2 Q2 o eee Motor Data Motortype 3 Indution 3rinduction Rotational speed min 1 1490 1450 Insulation 11 ClassF ProtectionClass 15
28. 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 drop The safety valve C 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 the by pass valve is stocked and lead water to the suction side of the pump Fig D 8 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 will drop depending of the size of the opening in seat NEPTUNE 5 EN Ver 2 0 25 11 30 Nilfisk ALTO Function Why Compromise A Hose connection valve seat B Non return valves C Inlet for water from water supply D Magnet piston for reed switch E E Reed switch for start of motor pump F Water inlet from pump G Non return valve magnet piston for H H Reed switch for start of heating system Water oullet J Back flow restriction Fig D 9 Flow control Water supply connected to the machine Water from supply passes the non return valves B and lift up the piston D Machine started
29. 2 4000 3 50 2 Current consump hot A 280 110130 154 10 30 Currentconsump cold A 82 110130 160 10130 Power Consumption hot kW 41 05 05 76 05 05 Fuse size A 160 16 0 Cord type HO7RN F 461 5 jHO7RN F4G15x6m Plugtype 7 CEE3P N G 16A CEE3PH N G 16A Control PCB24vit PCBAvak Contactor 100 C12KJ105 5kW 100 C16KJ1024 Electrical diagram __ 106427171 71371 106427171 J Eletrical test data Highvoltage HV test V 1000 100vac HV Resistance 7 24MO 50Vdc gt 1 0 500 Cord resistance Ohm Motortype 3 Indution 3rindution Rotationalspeed min 1 1450 140 Insulation ProtectionClass I P54 X P5 Nominal power kw 30 130130 67 30 30 08 o7 NEPTUNE 5 FA EN Ver 2 0 25 11 7 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Heating Unit Boilerpower_input kW o ao Temperature t Qinlet 12 852 00 Delta temp variance at 50 ea m set point at gun C 3 0 Boiler on time at 50 C set point Fm inlet 12 sec 30 0 5 0 5 0
30. 844 P854 Nominalpower kW 67 13030 67 30130 07 NEPTUNE 5 FA EN Ver 2 0 25 11 17 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Unit ek A ie Temperature tmax Qinlet 12 C 830 _ 430 00 30 EUREN Ll w uin set point at gun C 3 0 3 0 Boiler on time at 50 C A point Lal m inlet 12 sec 30 0 5 0 5 0 30 0 5 0 5 0 Steam temp t outlet and v Steam nozzle C 140 0 10 0 30 0 140 0 10 0 30 0 Pressure P2 outlet with standard nozzle 92 27 5 w 0 w 0 27 w 0 m 0 Fuel pump Fuel pump type Diesel Diesel 88 Nozzle size oil 1756vH 1060140 CO2 105 05 00 105 051 00 Efficiency burner 5 920 15105 920 15 0 5 Sootpitue w 013 J Exhaust outlet temperature 1750 100 100 1750 100 100 Exhaust temperature cut off CC 2700 00 120 2700 00 12 0 Fuel consump dT 45 deg kg h 46 00 01 46 00 01 Ee gt a leh 12 C inlet 7 3 7 3 124811124011 Water volume coil 1 4 8 4 8 Fuel tank Others Gun 1 STERGO2000 STERGO2000 Lace TORNADOPLUS TORNADO PLUS j DN10xf0mQuick3 8
31. NEPTUNE 5 FA Service Manual NEPTUNE 5 FA EN Ver 2 0 25 11 Nilfisk ALTO Preface Why Compromise This service manual contains detailed description of the main repair work on the hot HPW NEPTUNE 5 Repair work requires a suitable testing workplace with the necessary water and power supply If operating errors are evident refer the customer to the operating instructions A fault in the cleaner can have several causes as described in the section on troubleshooting Refer to the illustrated spare parts lists during repairs They show the assembly position and the sequence in which the individual components should be assembled See Service Technical Information STI sheets They include information on technical modifications that have been made after this repair manual was printed Service Technical Information sheets are also valid as a supplement to the spare parts list until publication of a new edition Repair manuals and Service Technical Information sheets should be available at the site where repairs are carried out It is not permitted to give them to third parties Use original Nilfisk ALTO spare parts only NEPTUNE 5 FA EN Ver 2 0 25 11 2 A Safety instructions B Technical data C Construction G Adjustment Test 49 53 H Wiring diagrams Special tools Spare parts Nilfisk ALTO Why Compromise For your own safety ESD measures electrostatic discharge NEPTUNE 5
32. c C decides the volume of water which is sucked through the suction valves E and pressed out through the pressure valves The inlet 7 and the outlet J are connected directly to the By pass valve The water volume can be adjusted by the regulation valve H NEPTUNE 5 FA EN Ver 2 0 25 11 2g Nilfisk ALTO Function Why Compromise Fig D 5 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 into the by pass housing C The water runs through the bottom of by pass housing and directely to the outlet I Due to the water pressure the by pass piston B is pressed up and the seat E is closed Fig D 6 By pass pressure Machine is started and the gun is closed By pass pressure When the J closes the pressure inside the by pass housing equalizes and the by pass piston 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 Due to the closed gun 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 5 EN Ver 2 0 25 11 29 Nilfisk ALTO Function Why Compromise Fig D 7 By pass pressure The by pass pressure is determined of the spring tension in valve The
33. ce aima s0ovae gt 50 Cord resistance Ohm ____ 2 ___ ____ O2 eee Motor Data Motortype 3 Indution 3 Indution Rotational speed 1 14560 X 1450 Insulation 1 Protection Class 41158 IP54 Nominalpower KW 67 130 30 67 30 30 07 08 NEPTUNE 5 FA 2 0 25 11 9 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Ife Tol Test result Tol Tol Heating Unit Boilerpower input kw 850 850 Temperature t 127 830 00 30 830 00 30 peewee lt ala mo set point at gun C 3 0 3 0 mo e mo inlet 12 sec 5 0 5 0 30 0 5 0 5 0 mo Steam nozzle 140 0 10 0 30 0 140 0 10 0 30 0 Pressure P2 a with sancar nozzle bar 27 0 5 0 5 0 27 0 5 0 5 0 Diesel Dies TT 120 105 00 120 05 00 1756 H 17560H 2 a 105 105 65 105 7195190 Efficiency burner 5 7 920 15 05 920 15 05 Sootpicture __ 044 0343 Exhaust outlet temperature p 175 0 175 0 Exhaust temperature cut off 270 0 00 120 C 0 en 00 129 Fuel consump dT 45 deg 46 __ Fuel consumption an gt LIL 48 ee
34. d leads it into the side of the boiler around and between the two jackets up to the air distributor In this way the air is preheated before it is mixed with the oil spray from the nozzle The cold water enters the boiler at the inner circle where the temperature is highest By doing so it will minimize the condensation of water on the surface of the tube Fe LONE ee FF m DEM kr Le 2 Pe ee puti il fff a 121 121 aga bud PEN n LE umo os Fig D 2 Hot water function The fuel is drawn from the tank through the fuel filter to the pump while in hot water mode it passes through the magnetic solenoid valve to the nozzle in the air distributor if combustion is required Fuel is returned to the tank if combustion is not required The ignition transformer is active in hot water mode and it will form sparks between the electrodes If the flame is not developed a flame sensor placed on top of the boiler will secure that fuel pump is automatically stopped and a fault code will be displayed on the panel When the machine is running normally and the boiler is burning normally the flame is pressed against the insulated bottom The temperature is here approximately 1100 C The hot exhaust gas is pressed further round the labyrinth shaped combustion chamber where the heat is absorbed by the water flow in the tubes
35. essure Outlet oar 0 73 9 9 16 9 19 Pressure Gun bar 818 8 8 gumias an lala m sle Cylinder Head bar ge mee mo aee ome Cylinder Head bar 250 0 5 0 5 0 250 0 5 0 5 0 Tyee 11 5 MNA i S Pistontype X Cemic Piston diameter rim Stroke Wobblediscange 102 ___ 102 ___ Cil BP Energol Oil BP Energol Pump oil type XP220 XP220 Oil volume I Electrical Power supply 400V 3 5OH2 4000 3 50 2 Current consump hot 122 10 30 123 10130 Current consump cold A 124 10 30 125 10 30 Power Consumption hot kw 60 05105 61 05 05 Fuse size A o 160 160 Cord type 4615 jHO7RN F4G15x6m Plug type 6 16 CEE 3P N G 16A Coto o PCB24vl PCB2Zvot Contactor 100 C16KJ1024 100 C16KJ1024 Electrical diagram 106427171 106427171 J Eletrical test data Highvoltage HV test V 1000Vac 1000 HV Resistance 21MQ 500Vdc 1MQ 500Vdc Cord resistance Ohm 1 00 0 0 Motortype 3 Indution 3rinduetion Rotationalspeed min 1 1450 _ 1450 Insulation o
36. essure Nozzle NTOS00 NoiselevelimLpa dBA 766 15 15 766 15 15 Noisepower LWA dB A 930 15 15 930 15 15 impact a NO a a aH Vibration ISO 5349 225 2 2 ProtectionClass IPX5 IPX detergent flow from full internal tank 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 2 0 2 0 2 0 2 NEPTUNE 5 EN Ver 2 0 25 11 6 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Pump Data Max inet pressure ban _ Inlettemperature 400 J Pressure atpumphead 0 75 24 4 190 710 10 Pressure Cylinder Head ban 0 550 44 195 711 11 Pressure Quilt ber B 440 Pressure Gun bar 0 67 4 4 8 2 1 Cylinder Head bar Jor 120 0 5 0 5 0 250 0 5 0 5 0 Flow Qiec Flow l min sd 2 5 121 1 03 3 0 3 3 158 __ 8 04 4 EPI 4 Flow Qmax vmin ______ 5 134 POZ POZE 169 _ 08 08 Type NAS NA Peston type aie Piston diameter mem 1 3 Stroke Wobblediscange 9 2 Oil BP Energol Oil BP Energol Pump oil type n XP220 7 220 Oil volume 1 Electrical Powersupply 400 3 50
37. esult Tol Tol Test result Ife Pump Data inlet pressure bar 100 J 100 Inlet temperature 400 400 Pressure atpumphead 0 195 1 1 190 10 10 Pressure Cylinder Head bar 0 200 11 11 195 11 Pressure Outlet bar 70 2 168 ___ umen om sn Cylinder Head bar pee to ayinde EM 250 0 5 0 5 0 250 0 5 0 5 0 04104 7158 98 98 G HIR ta Tye NAS Pistontype ston ameter _ Stroke Wobblediscange 120 120 ___ Cil BP wana Oil BP Energol Pump oil type 7 XP220 XP220 Oil volume I Electrical Power supply A00V 3 50Hz 40703V3 5Hz Currentconsump hot A 158 10 30 156 25 10 30 Currentconsump cold A 160 10 30 158 25 10 30 Power Consumption hot kW 78 0505 76 74 05 05 Fuse size 160 28 00 Cord type 7 HOTRN F4G15x6m HO7RN F4G25x60 Plugtype 1 CEESPNNG T6A ___ Control PCB Avot PCB 24volt Contactor 7 100 C16KJ1024 100 C23KJ10 Electrical diagram ___________ 106427171 106427177 Eletrical test data 100 100Va HV Resistan
38. esult Tol Tol Test result Tol Tol Pump Data inlet pressure bar 100 15900 Max Ie temperature Pressure at pump head gt ELI ua m lala bar 200 11 11 162 pressure Pressure Outlet 7 L e MO Ec w Cylinder Head bar mo so se Cylinder Head bar 250 0 5 0 5 0 250 0 5 0 5 0 Flow Qmax mn 7 5 767 0808 7445 07 7 Tye 71 5 NAS Pistontype piston diameter mm 1 Stroke Wobble disc angle 722 891 13 7102 7 l n Pump oil type GR XP220 GR XP220 Oil volume I Electrical Powersupply __ 400V 3 50Hz 200V 3 50Hz Current consump hot A 154 110 30 187 10 30 Current consump cold A 160 110 30 189 10 30 Power Consumption 105 espas Fuse size A 160 0 200 7 0 Cord type HO7RN F 4G1 5 x 6m 4x3 5x6m L T EE Contactor 100 C23KJ10 100 C3024V 50 60H Electrical diagram 106427171 106421534 po Eletrical test data Highvoltage HV test v 10045 400Vac HV Resistance 2 500 4 2 1MO 500Vdc Cord resistance Ohm ____ 2 ee Motor Data Motortype 3 idutin ___ Induction Rotationalspeed min 1 1 1450
39. ide it supplies the actors contactor relay solenoid valve anti stone pump with 24V AC The transformer T1 supplies the system with 24V and 8V AC 7 is the connector to a remote control which is available as an accessory X2 is the connector to the Nilfisk Alto Datalogger and to service interval settings Detailed function is described in chapter D Detailed adjustment is described in chapter G Electrical diagrams can be found in chapter H 1 Switch for change of temperature display X9 Hour display setting Celsius fahrenheit X10 By pass time canceling 2 Switch for by pass setting when connecting a remote control X7 Remote control X2 Data logger B 7 5 1 9 Y2 B 1 K2 B 6 K1 B 4 Fig C 7 PCB 1 Y1 B2 MI 24V 8V FuseFi Fuse F2 NEPTUNE 5 EN Ver 2 0 25 11 22 Nilfisk ALTO Construction Why Compromise 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 super heating Flame sensor Electrodes Fuel nozzle Exhaust Water outlet Water inlet Top plate Air
40. in cold hot water mode When piston 0 is lifted up by the flow the magnet in piston D closes the reed contact NO E which gives a signal to the PC board which starts up the motor pump unit The flow from the pump lifts up piston To secure the flow is all right the magnet in piston closes the reed contact NC H which gives the signal to the PC board In hot water mode this signal controls the fuel solenoid valve and the anti scale pump The fuel solenoid valve and the anti scale pump will activate when the PC board receives the signal from reed contact H Piston When the is closed piston closes the inlet of the flow control Inside the piston there is a retaining valve which opens when the outlet pressure in the flow control is more than10 bar higher than the inlet pressure when the gun is released This pressure differens will improve the movement of piston G when the gun again is activated NEPTUNE 5 EN Ver 2 0 25 11 31 Nilfisk ALTO Troubleshooting Why Compromise When trouble shooting it will be a great help if you can locate the fault as being either an external fault or an internal fault External faults are due to either improper maintenance incorrect operation or operation under parti cularly straining conditions External faults usually represent the following The below mentioned conditions have been checked and found ok Check point 1 Installation fuse blown C Pl
41. l block pistons and valves in the pump or get stucked in the non return valve in the unloa der Fig F 25 Damaged header ring NEPTUNE 5 FA EN Ver 2 0 25 11 42 Nilfisk ALTO Why Compromise Service Repair Wobble disc Fig F 26 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 28 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 5 FA EN Ver 2 0 25 11 Fig F 27 D bearing cover wobble disc Overview of the parts inside the D bearing cover Fig F 29 Wobble disc removal Demount the wobble disc screwing a 16mm bolt into the threads Tighten the bolt against the motorshaft and pull the wobble disc out 43 Nilfisk ALTO Service Repair Why Compromise Bearing system Fig F 30 Bearing track removal Fig F 31 system amp woble disc Remove bearing track in D bearing cover Replace the complete wobble disc system and make sure parts are as sembled according to instructions Fig 32 8 Fig 33 pos amp A B m pa if atl Fig F 32 Bearing track Fig F 33 Bearing track The curved edge A of the bearing tracks The sharpe edge B of the bearing track
42. mp toms are that the machine smokes during steady operation Cause 1 Air deficiency Remedy Check air adjustment and fan attachment to boiler Cause 2 Bad oil air mixture Remedy Check oil pressure and oil quality Replace the oil nozzle Adjust air diffuser Cause 3 Unfinished combustion Remedy Check bottom insulation boiler top gasket between tube and inner boiler jacket in top ver Check burner tube Cause 4 Unstable ignition Remedy Check electrodes Adjust the air quantity less air Cause 5 Leaky solenoid valve on pump Y1 Remedy Check replace solenoid valve 1 Low oil pressure Cause 1 Incorrect adjustment Remedy Adjust pump pressure 12 bar see page 45 Cause 2 Filter blocked defective pump Remedy Replace filter oump Empty and clean tank Full water quantity at steam stage Cause Mechanical defect of by pass valve or adjustment Remedy Check by pass valve NEPTUNE 5 EN Ver 2 0 25 11 35 Nilfisk ALTO Service Repair Why Compromise Observitions Fig F 01 Data Plate Fig F 02 Water filter Cleaning e Prior to any maintenance identify the e As required clean the water filter machine version at the data plate e Unscrew connector for water break tank e The data plate is situated in two places at the e Pull out the filter by use of a nose pliers machine e Clean the filter and inspect for damages e External Back left hand side e Clean the filter e Internal
43. n dings Flow Failure Flow switch B2 closed and Wire defective in B4 open ging Flow piston han Reed switch Wire defective Spark failure Oil filter blocked soot on glass Fuel Empty Levelswitch Open _ Wire defective B9 switch Leakage Three times start without flow Water in electric U processor failure system Open Air in suction water No water No Light Fuel Enabled Light sensor B7 see no light when Y1 is open Fuse F11 Flow switch off Sensor B7 Leaky non return Leaky system B4 switch valve Flow switch B2open and flow switch B4 close Detergent valve NEPTUNE 5 EN Ver 2 0 25 11 34 Nilfisk ALTO Troubleshooting Why Compromise Boiler performance The symptom is reduced performance of the pump effect or the boiler effect The symptom of redu ced boiler effect is a lower water outlet temperature than the set value The possible causes for this are as follows Scale deposits in boiler tube Scale formation acts as insulation and reduces heat transfer to the water The result is raised flue gastemperature increased flue gas loss Cause The hardness of the water Remedy Descale boiler tube Sooted boiler tube Soot has the same effect as scale deposits i e that they are both insulating against the heat trans fer to the water and results in increased flue gas temperature increased flue gas loss Other sy
44. o bypass Then you turn the adjusting screw a 1 2 turn back Clockwise and lock it with the counter nut Open and close the pressure gun a couple of times to check the adjustment Finalize the adjustment with locking glue paint on both the bolt and the safety valve 51 Nilfisk ALTO Adjustment Test Why Compromise 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 tem perature 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 327 which mea sures and displays all relevant data If the measured value is too low close the air flap a little and check the soot
45. of the valve cone inside the water regulation special tool no 1210558 can be used Fig F 09 By pass water regulation By assembling and disassembling of the parts in the by pass system be aware of the order of the components Fig F 11 By pass water regulation By reassembling of the water regulation knob special tool no 1211697 can be used NEPTUNE 5 EN Ver 2 0 25 11 38 Nilfisk ALTO Service Repair Why Compromise Valves Fig F 12 Valve housing Dismount the valve housing from the cylinder block by the three M12 bolts Be aware of the o rings and valve parts Fig F 14 Valve housing Carefully tip out the sleeves with an adequate screwdriver and replace them Be careful not to scratch the surface NEPTUNE 5 EN Ver 2 0 25 11 Fig F 13 Thrust collar Be carefull not to damage the surface inside when dismounting the thrust collar Inspect the thrust collar for damages before mounting Puller used in the picture is Bahco 4521N F Fig F 15 Valve housing Knock carefully on the back side of the valve seat to demount it or use an 8mm threaded pin and pull it out Replace with new parts 39 Nilfisk ALTO Service Repair Why Compromise Valves Pic F 16 Suction valves Pic F 17 Pressure valves Overview of the placement of suction valve Overview of the placement of pressure parts valve parts Fig F 18 Pressure
46. oid valve To run the machine on hot water the following must be ok on the front panel S1 and the temperatu re setting on hot and the spray handle open If all the sensors are closed and ok K1 will start the mo tor and K2 the ignition and fan Y1 will open and let in oil to the combustion chamber If the flow stops B2 will open and the 24V supply to the solenoid Y1 will be interrupted and the combustion will Stop NEPTUNE 5 EN Ver 2 0 25 11 27 Nilfisk ALTO Function Why Compromise E ki LEM _ lt b m E pe er Ss et Da Bi l 25 E PIN jm i 2 38 M D ON 3 i 4 E H 1 5 5 1 1 P 1 i 1 ko 1 7 d i 4 v kr L F E Em T 1 m IL r x LE 1 1 ESL 4 1 E ig S mu r1 Hem 2 gm yi 1 Fig D 4 Motor pump A Stator E Suction valve B Rotor F Pressure valve C Wobble disc G BY pass housing D Ceramic piston H Water regulation valve The three ceramic pistons D are driven by a wobble disc the mission of which is to transform the rotating power from the rotor B into the reciprocating pumping pistons D The angle of the wobble dis
47. one Gun 1 STERGO2000 STERGO2000 Lace 1 5 TORNADOPLUS Hoe DN80m3 DN8xX20m38 High Pressure Nozzle 0550 NT050 NoiselevelimLpa dBA 782 15 15 782 15 15 NoisepowerLWA GB A 960 15 15 590 15 15 Impactforce 9540 530 Vibration ISO 5349 m s s25 25 Protection Class ___ IPX Max detergent flow from full internal tank 96 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 2 0 2 0 2 0 2 NEPTUNE 5 FA EN Ver 2 0 25 11 10 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test result Tol Tol Test result Tol Tol Pump Data inlet pressure bar 100 90947 Inlet temperature 400 460477 Pressure atpumphead 0 195 11 111 190 710 10 Pressure Cylinder Head bar 0 200 1111 1 5 Pressure 20 s Ou Q Gun c 170 0656 EE xa x lala Cylinder Head bar Ere to eynde 250 0 50 5 0 250 0 5 0 5 0 Flow min ______ 5 169 08 08 169 _ 08 08 Type NS T C NS T T Pistontype J J Piston diameter mm 200 200 Stroke Wobble disc angle 120 89 113 99 89 113 Oil BP Energol Oil BP Energol Pump oil type 220
48. outlet and v Steam nozzle C 140 0 10 0 30 0 140 0 10 0 30 0 Pressure P2 outlet with standard nozzle bar 27 0 5 0 5 0 27 0 5 0 5 0 Fuelpumptype Diese 1 Diesel ME Oilpressure bar f 70 05 00 720 05 00 Nozzle size oil 1756 17560 Sozeononmu 02 j te ti Etfciencybumer _______________20 15 055 m 15 05 Sootpicture n xus Exhaust ouletiemperature 1 159 loojoo 7759 4001109 temperature cut T 270 0 120 270 0 Fuel consump dT 45 ran aR _ 46 46 asss 12 C inlet 7 3 7 3 48 48 Water volume in coil l Fuel tank D ti Others Gun STERGO200 STERGO200 _ Lance TORNADOPLUS __ Hoe J DN82m3 8 20 3 8 High Pressure Nozzle 0550 550 _ Noise level 1m Lpa dBA 782 115 15 782 15 15 Noisepower LWA dB ________ 960 15 15 90 15 15 Impactforce O Z 540 530 Vibration ISO 5349 m s 25 25 Protection Class IPX a detergent flow from full internal tank 1 0 1 0 1 0 1 0 Max detergent flow from full internal tank L min 0 2 0 2 0 2 0 2 NEPTUNE 5 FA EN Ver 2 0 25 11 12 Nilfisk ALTO Technical data Why Compromise NEPTUNE 5 FA Technical data Test r
49. rating and Co2 content again Repeat all settings until all specified values are obtained 5 Finally seal the set screw arrow A of the air flap with varnish Fig G 15 Fuel pressure setting eMount pressure gauge on the fuel pump e The air flap on the side of the burner fan is Adjust the fuel pressure according to the va adjusted by a self locking spindle on a set lues in Technical data chapter A screw Turning clockwise increases the air intake turning counterclockwise reduces it NEPTUNE 5 FA EN Ver 2 0 25 11 52 Nilfisk ALTO Why Compromise 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 Fig G 19 Service settings NEPTUNE 5 EN Ver 2 0 25 11 Adjustment Test Fig G 18 Burner measurements The 2 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 327 4 which measures and displays all relevant data If the measured value is too low close the flap Fig G 06 a little and check the soot rating and Co2 content again Change temperature display When 1 is on the temp Is shown
50. ture sensor is fitted with If the exhaust temperature reaches 270 C 2 screws in the exhaust 518 F the machine cuts out The relay pla ced in the E box can be reset by pressing the green button Burner Unit Fuel solenoid Fuel pump Burner motor Burner housing Fuel filter Fan Fan cover 202702200 Fig F 44 Burner unit NEPTUNE 5 FA EN Ver 2 0 25 11 47 Nilfisk ALTO Why Compromise Service Repair Heat exchanger Fig F 45 Dismounting 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 When landing on the floor press over to the side or protect the machine by a piece of card board Fig F 47 Dismounting coil Check the flame tube A and B It is important that they are solid and whole NEPTUNE 5 EN Ver 2 0 25 11 Fig F 46 Dismounting coil Attention Be aware of the fact that the machi ne can tip over Keep the coil close to the ma chine Clean up deposits and change the isolation if needed 48 Nilfisk ALTO Adjustment Test Why Compromise Torque specifications 20 Nm Fig G 01 Wobble disc 65 Nm 10 Nm S 599 C Fig G 05 By pass housing 40 Nm Fig G 07 Outlet fittings NEPTUNE 5 FA EN 2 0 25 11 Fig G 08 Water regulation 820 Nm By hand 49 Nilfisk ALTO Adjustment Test
51. ug defective 2 Plug defective Il S Cable bursting Too long to small or defective extension cables 5 High low pressure nozzle blocked or worn 0 y O ___ 6 Spray handle defective or leaky P x 7 High pressure hose too long or defective 4 4 4 4 ___ _ _ ___ _ dmm Nimm 9 Inadequate supply of mains 4144 n 10 Air sucked into the pump detergent tank empty 414 VN 11 Detergent system blocked died up 000000000 12 Inletwatertoohot 0002 x 13 Fuelfilterblocked ___ dq 14 Air adjustment fauity x n 15 Fuel level low Waterintank L C f y O 8 Water inlet filter blocked dirty water The internal faults require a systematic going through of the motor pump by a Nilfisk ALTO technician In order to establish the reason of the fault with certainty it may be a help to use the over leaf yes no diagrams NEPTUNE 5 FA_EN_Ver 2 0_25 11 32 Nilfisk ALTO Troubleshooting Why Compromise Below there is a list of the actual detectable errors with the belonging code The codes SEO SEC LHE and FLF only occure in Hotwater operation Error describtion Code Error micro processor uProcessor Temp sensor closed Short circuit Sensor closed Tempsensoropon Sensor open SEO Flow sensor for start open flow sensor for hot ater closed
52. valves Fig F 19 Pressure valve seat The pressure valves can easily be taken Take out the pressure valve seats with out of the cylinder head an adequate puller Replace with new parts if necessary Replace with new parts if necessary Puller used in the picture is Bahco 4521N 00 NEPTUNE 5 FA EN Ver 2 0 25 11 40 Nilfisk ALTO Service Repair Why Compromise Cylinder block Fig F 20 Cylinder block Fig F 21 Oil Sleeves Overview of the placement of the parts in Take out the oil sleeves using an the cylinder block adequate puller Be careful not to damage the surface of the cylinder block Puller used in the picture is Bahco 4521N F Oil seal and piston Fig F 22 Valve Kit 3 Exploded View Fig F 23 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 5 FA EN Ver 2 0 25 11 41 Nilfisk ALTO Service Repair Why Compromise Replacement of secondary seals and header rin Pic 9 Showing the right position of the header ring Knob on header ring must be placed in groove against the centre of the cylinder head If the header ring is mounted wrongly and not according to instruction there is a big risk of damaging the header ring and parts of it wil
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