A - Frontpage - N4.pub
Contents
1. 41 6 1605 VA MOO e s 43 Eg EEUU ULM 44 Heating system 44 Exhaust temperature 45 Uie Bf ean 45 Heat exchanger 46 Torque specifications 47 Adjustment of by pass system 48 Burner settings 50 BE e ua aaaa 52 Service time settings 52 diagrams 53 NOIES Lee 62 NEPTUNE 4 FA EN Ver 2 0 22 11 Nilfisk ALTO oafety instructions For your own safety ESD measures electrostatic discharge NEPTUNE 4 FA EN Ver 2 0 22 11 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 use2. Max detergent flow from full internal tank 4 lH ETER Max detergent flow from full internal tank L min 0 38 0 2 0 2 EEN MB nS ECKEN Pes Approved by _ gt SLG Chemnitz Chemnitz Approvals sas ss Oil pressure Nozzle size oil CO2 content min Efficiency burner 96 Soot picture Exhaust outlet temperature C Exhaust temperature cut off C Fuel consump dT 45 deg kg h NEPTUNE 4 EN Ver 2 0 22 11 8 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 FA Technical Data Test Result Tol ke Test Result Tol Tol Test Result Tol Tol Pump Data Max inlet pressure bar D p e 7j Max Inlet temperature C 40 gt ___ 4 5 50 Pressure at pump head 5 50 Pressure Q Cylinder Head bar 162 181 10 VL ous 48 or Pressure Q Outlet bar 148 166 9 VL me ula er Pressure after Gun bar 132 71 7 144 8 Pressure cut off Cylinder Head NN bar 182 201 5 Pressure Pmax safety vave 250 2 90 Flow Qmax l min 5 EE 7 0 7 7 14 EZ 7 FI 7 3 00 Type ms Piston type corme cereme Seems I _ Piston diameter mm _ 2 Stroke Wobble disc angle 8 I 1028 102 Pump oil type 220 220 Oil v
3. 21 Je AES uai L us i rH EXT EXP a Pol M 58 NEPTUNE 4 FA EN Ver 2 0 22 11 RR mi DE i ez labot 9 angad 781279901 Bulan Al XQ paparde 21558 Je45 Ude Y4 M F ss 11443813 1 WP I iss se eg rade ATS erur go ESl B002 JdH pabueu sg 29 1216408 usa mapas eo 12219 E 43219 1 32219 1 47219 p 42819 5 45819 E 5 4219 7 42914 EI 42919 iagrams Z 41219 E Z 41279 L 3181 o 1 3018 TeHIMa 3L d iring dund 4 dund jin LA 49119154244 el SUBJ L 10 104384040 ewa LM LIB zH JoJo IW SEE 491281197 aind Edred dua 4502473 J05Ua5 aL LH YIJIMS 0943 7465 TH AO 28 IB 49 944402 3ILID 412813 19 Jd lT Nilfisk ALTO Why Compromise 20 34 Ana 59 NEPTUNE 4 FA EN Ver 2 0 22 11 Nilfisk ALTO Why Compromise d iagrams iring Fun Em T gz farbar oade miayo BO OL AD iu 18122790
4. Vibration ISO 5349 m s ms 10 8 Protection Class es pe es peses feshe xs Max detergent flow from full internal tank __ PHEB 4 Max detergent flow from full internal tank L min T EN s EE gros Approved by SLG Chemnitz Chemnitz SLG Chemnitz Chemnitz Approvals CE a RSS NEPTUNE 4 FA EN Ver 2 0 22 11 10 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 FA Technical Data Test Result Tol ke Test Result Tol Tol Test Result Tol Tol po tt Max Inlet temperature C 4 mE 40 40 __ 40 5 50 5 50 5 50 E mn P fas fas gt Pressure after Gun bar 8 9 9 Pressure cut off Cylinder Head bar EL EN _ pm 2E Pump Data Max inlet pressure bar Pressure Pmax safety valve 20 5 5 20 as 5 25014511 25 90 Flow Qmax l min 5 14 446 071 TI FI 7 530 30 0 8 8 0 8 1530 30 0 8 8 0 8 3 00 Type Piston type Piston diameter mm ET BP Energi GR BP Energol GR at BP Energol GR at 220 220 220 Electronics Elec V Ph Hz cole Current consump hot A 124 225 105 Current consump col 1267232 128 10 30 Power Consumption hot kW hot 6 2 6
5. 0 2 lt Flow Qmin steam l min e D 5 Piston type N Piston diameter mm Stroke Wobble disc angle o e 8 7 Oil BP Energol GR XP 220 0 95 Pump oil type Oil volume 1 Electronics Elec V Ph Hz Current consump hot A 400V 3 50Hz Current consump cold A Power Consumption hot KW hot Fuse size A oa 4 Cord type HO7RN F 301 5 x 6m ae Plug type 16 Schuko CEE7 16ASchuko CEE SP N G 16A Contro pg PB re _ Control voltage 24 Volt Control voltage 124 Volt Control voltage 24VoltControlvotage Contactor 100 012KJ105 5kW 100 C12KJ1055kW 100 012KJ105 5W _ Electrical diagram 106427170 106427170 106427170 oova 1000 100 gt 21 0 500 z1MO s0Vdc e1MO S0Vdc gt induction 3 mdueton Induction _ J 19 w j _ dcesF CesF _______ mg j m _ Pa 1 J 2 GJ 5 o5 os os Eletrical test data Highvoltage HV test V HV Resistance MQ Cord resistance Ohm Motor Data NEPTUNE 4 Ver 2 0 22 11 5 Nilf
6. 3 5 E 0 5 0 5 otroke Wobble disc angle Pump oil type Oil volume 1 Fuse size A NN 25 16 Cord type Plug type GEE3P NHG 16A _ Contro a J Control voltage 24 Volt Control voltage 24 Volt Control voltage 24VoltControlvotage Contactor 100 C12KM05 5kW 100 CT2KJ05 5kW 100 Electrical diagram xs 1064271474 106427170 106427170 dove gt 21 0 500 1mQ s00vde e1MO sSOVdc gt induction 3 Indw on 3 induetion 10 1460 w j _ _ Pak mg j j P j j pg J 55 85 J o5 os os Eletrical test data Highvoltage HV test V HV Resistance MQ Cord resistance Ohm Motor Data NEPTUNE 4 2 0 22 11 11 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Tol Tol Test Result Tol Test Result Tol Tol Heating Unit Boilerpower input KW o e e 6 Temperature t 12 CC Jalal z ma nv Jaa Tu g fafa o x lads gun C 30 2 3 30 2 3 30 2 3 p
7. cacy ONE o ee paese Sen TETTE Eyal uoxqw M JUDI 40 vJ wou Med 509 90 que puwa x x UU Fa 2144299 ee a 8 mapan ee Lab ey an 12079 TYNIHY3L dund dund u amp iaunp AWOL SUE Lini Jiu 0 JS LIE I YME uasan 210491591 96421251 JOJ U 494294949 ewag JD UI LIP App 40422197 an YILIMS Way 4sngux Jo 0 ung 19503 DUE doje 91 105095 J ueyesadg 9d ADEE 60 NEPTUNE 4 Ver 2 0_ 22 11 Nilfisk ALTO Why Compromise d iagrams iring ELE umm wxh Ta wem 79177790 U 102 penizeds WIS 57 Dell d SH 00000 4 V4 WEJDEID 11143913 _ aaa s E ALS us 002 roads EFE Moran ES 600c IdH o 99M Usa uaa Bae GO 47214 9 5 42214 4 H
8. am aun day roads AS zm Jer iud 91 6002 29 BOD poke pue 29 991 600 14 xxr 1 19 su05 0 E T ae 4g AQ L Hx3 54 NEPTUNE 4 FA EN Ver 2 0 22 11 susp ud ala sm FR EL DUE mz alboz V aunjdap vaade ECE 09 HEI m Sansa B 4g z Bulun l EAL DJ PH wes di EGGE p ue gs o sunl SEG 55 Nilfisk ALTO Why Compromise d iagrams iring H 42219 25 L 43219 25 L yq 9 47219 o 9419 42819 Qi 5 4210 T E 749 E512 4219 2078 dund pg L ued uni JUN LIS EVES VALUE ZI 516 LL HT PUG uas 5 10478401 JE Way JOJOW Jang Zh IH ZH JD 2400 UM EJ 24 14 Tang 4291 9415 UR uM 10911 19595 LB duind 341 eu 4i 5 dura L HX3 lays 0045 4845 TH Mar 195129 LE JajjoJJ
9. TORNADOPLUS920 Hose pN amp xiomQuck 38 DbN amp dem __ High pressure nozzle No50 NT 0500 EE Noise level 1m Lpa dBA H5 5 _ 756 1451 15 Noisepower LWA dB A 9 fasas o Jasas Impact force a 4 Jj J Vibration ISO 5349 m s Protection Class ds len ex Jens lene Max detergent flow from full internal tank ETE FEN Max detergent flow from full internal tank L min 088 402 0 2 0 55 Approved by secemu apt MEME Approvals s gt acs NEPTUNE 4 FA Ver 2 0 22 11 16 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 FA Technical Data Test Result Tol Tol Test Result Tol Tol Test Result Tol Tol Pump Data Max inlet pressure bar Max Inlet temperature C 40 5 90 P tail a e bu Pressure Outlet bar 9 140 8 o ome eere Pressure after Gun bar 8 dl m als m m bar 201 5 5 178 o 5 211 5 5 Pressure Pmax safety vave 2560 5 5 260 _ 5 250 5 5 2 90 Flow Qmax l min 0 71 1250 106 06 ETT ET Type EE JE NAS _ Piston type Ceamc Ceamc Cerme gt Piston diameter mm RB Stroke Wobble disc angle 109 9 er M d Pump oil type 220 220 220 Oil volume 1 ____ 095 ___ Electronics Elec V Ph Hz 75
10. 6 4 6 6 5 0 5 0 5 0 5 Pump oil type Oil volume 1 Fuse size A an ___ 0 Cord type hus Plug type Control pg PB re _ Control voltage 124 Volt Control voltage 124 Volt Control voltage 124 Volt Control voltage Contactor 100 c12kJ105 5kW 100CT2Kj055kW 6420832 _ Electrical diagram P 106427174 106427174 1 106420541 Eletrical test data Highvoltage HV test V 400Va 1000v ve HV Resistance MO 21 0 500 1mQ s00vde gt gt 3 mdueton _ 1450 _ H9 Csr Pak mg j j _ pms se __ 5 o o j os Cord resistance Ohm Motor Data NEPTUNE 4 EN Ver 2 0 22 11 13 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Tol Tol Test Result Tol Test Result Tol Tol Heating Unit Boilerpower input KW Temperature t max inlet 12 C l gun C 30 0 30 0 Boiler on time at 50 C set point inlet 12 30 5 5 30 5 See eee a fola steamnozzle C 140 10 30 140 10 30 140 10
11. Check the flame tube A and B It is important that they are solid and whole NEPTUNE 4 FA Ver 2 0 22 11 Fig F 48 Inspection of coil Clean up deposits and change the isolation if needed 46 Nilfisk ALTO Adjustment Test Why Compromise Torque specifications 320 Nm DN VM 74 Fig G 01 Wobble disc 65 Nm 10 Nm b mcd nd DP Fig G 05 By pass housing 40 Nm A Fig G 07 Outlet fittings NEPTUNE 4 FA EN Ver 2 0 22 11 47 Nilfisk ALTO Adjustment Test 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 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 4 FA EN Ver 2 0 22 11 48 Nilfisk ALTO Adjustment Test Fig G 13 Pressure bolt When
12. Fig C 9 Motor Pump unit The NA 5 three piston axial pump used in Neptune 4 FA 15 build in line with the electrical motor as one compact unit m 4 I nC s Fig C 10 By pass valve Fig C 11 Flow control The flow control checks if there is flow in the The start stop system in Neptune 4 FA is flow system to stop and start the machine Activated NEPTUNE 4 FA_EN_Ver 2 0_ 22 11 22 Nilfisk ALTO Function D If the machine and the power supply are working correcatly the following will happend during start up Start cold Start hot STONE O 209 i3 9 Nilfisk ALTO gt 0 t Detergent valve Fig D 1 Display The main switch 51 functions on off temperature setting is turned to Cold water mode AC vol tage is applied across the main switch S1 to the control transformer T1 This supplies 8 Vac and 24 Vac to the control board microprocessor A1 the processor itself works on 5 Vdc Once the 5 Vdc operating voltage of the processor is stable it tests the following sensors thermal release B3 thermal protector MT level of pump oil B6 This causes all status display LEDs to illuminate for 1 s If one of these sensors Is open circuit the motor is not powered on The supply voltage is applied to the main contacts 1 3 5 of the contactor K1 for the electromotor M1 Once all initial
13. e Vibration ISO 5349 m s Protection Clas LE px s Boilerpower_input kW Max detergent flow from full internal tank 1 4 l FEREB ENE Max detergent flow from full internal tank L min EN x s m EN cs wa mE Approved by SLG Chemnitz Chemnitz SLG Chemnitz Chemnitz Approvals i e 1 9 sa NEPTUNE 4 FA EN Ver 2 0 22 11 18 Nilfisk ALTO Construction Neptune 4 FA Variants Single phase 4 28FAX Expt 4 31 FAX EU 4 37FAX USA 4 28FA Gerni Three phase 4 39FAX EU 4 43FAX EU 4 47FA JP 4 50FA EU 4 50FAX EU 4 50FA NO 4 55FA EU 4 55FAX EU 4 55FA Expt 4 55FAX Expt 4 55FAX Gerni 4 50FA Expt X vs Standard Hose Reel and Hose lenght 15m on X models _ These numbers refer to the theoretical total impact of spraying water calculated by the formula Impact Q1 x V P1 x 0 22 N P1 bar Q1 l min v FA Flow activated start stop system The Neptune 4 FA is build with an 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 3 4 models Burner fan housing Fuel pump Anti scale pump Boiler Fuel filter Flow control oafety valve Pressure water regulation By pass valve Electrodes Ignition transformer Boiler outlet with temperature sensor NEPTUNE 4 FA EN Ver 2 0 22 11
14. 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 4 FA EN Ver 2 0 22 11 28 Nilfisk ALTO Function D Fig D 7 By pass pressure The by pass pressure is determined of the spring tension in valve A 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 rise 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 K will drop depending of the size of the opening in seat NEPTUNE 4 FA EN Ver 2 0 22 11 29 Nilfisk ALTO Function D 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 fro
15. Fig C 2 Top view Boiler inlet Flame sensor Fuel nozzle Exhaust thermal safety sensor 17 Nilfisk ALTO Construction dr C 7 y Fuel filter oide cabinet right External deter gent Fig C 3 Frame amp cabinet parts NEPTUNE 4 FA EN Ver 2 0 22 11 18 Nilfisk ALTO Construction 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 temperature adjustment and five status warningLights Fig C 4 The cover is sealed around the edge and around the manometer and the detergent valve s 40 a 4 Adjustment Temperature settings Service interval settings Fig C 4 Operation panel Display board A2 E S Fig C 5 Panel inside Fig C 6 Electrical box NEPTUNE 4 EN Ver 2 0 22 11 19 Nilfisk ALTO Construction The electric control system is built up around the control board which is divided into two stems a 5V DC system on one side to supply the sensors B8 B4 B6 B1 B9 B7 and on the other side 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 X2 Is the connector to the Nilfisk Alto Datalogger and the service setting jumper Detailed function is described in chapter D Detailed adjustment is describ
16. NEPTUNE 4 FA EN Ver 2 0 22 11 7 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Tol Tol Test Result Tol Tol Test Result Tol Tol Heating Unit Boilerpower input KW Temperature t Qinet i2 CC fafaj 2 fafa tg 4 ere s x ela gun C 30 0 3 30 0 3 30 0 3 5 5 30 0 3 30 5 5 10 30 10 30 10 30 steamnozzle C Pressure P2 Q outlet v standard nozzle bar 5 5 1 Dies Fuel pump type 1 0 60 H 1 0 60 H M pod 1 EM ONE 60 H 405 40 5 0 105 0 5 0 405 MEL 92 5 08 o _ 145 160 t0 40 me Til 3 el oe Jw 27 1001011 23 J00 01 39 foo fo Fuel consumption kg h 12 C inlet 41 00 00 a Joo oo 52 00 00 Water volume in coil 1 34 34 34 Fuel tank 1 15 _ 15 __ 15 45 Others Gun STERGO2000 STERGO 2000 STERGO2000 Hac cs Lance 940 940 920 Lo ELI Hose DN 8x15m DN 8 x 15m 3 8 High pressure nozzle NT 0450 NT NTOMO NT 0500 Noise level 1m Lpa dBA Es or ST ME Noisepower LWA dB A 3 Impact force pu a 2 42 _ Vibration ISO 5349 m s 10 Protection Class
17. Approved by mE SLG Chemnitz SLG Chemnitz Chemnitz SLG Chemnitz Chemnitz Approvals n GS CE GS NEPTUNE 4 Ver 2 0 22 11 12 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 FA Technical Data Test Result Tol ke Test Result Tol Tol Test Result Tol Tol Pump Data L 409 tt Max inlet pressure bar ap o 5 50 a to _ _ vas o 5 50 _____1 ___ m Der 5 50 pressue Ouet oay e so podao er 5 50 Pressure after Gun bar 9 9 9 m m olal om m bar 211 5 211 5 191 5 Pressure safety valve 20 as 5 20 as 5 20 5 5 Flow Qmax I min 5 1530 30 0 8 8 0 8 453 30 0 8 8 0 8 12 1240 0 6 6 0 6 Type NAS NAS _____ NAS LE Piston type Cm Cmm tmm _ Piston diameter mm Stroke Wobble disc angle 945 15 Oil BP Ed GR XP Oil BP Enea GR XP me Oil BP Fea GR XP Electronics Elec V Ph Hz 440 220V 3 l6OHz 440 220v 3 e0Hz 230 1 60 gt Current consump hot 2241122 __ 10 30 2251124 __ 10 30 253 00 30 Current consump cold A 234 126 __ 10 30 2341128 10 30 268 ___ 10 3 0 Power Consumption hot kW hot 6 3 6 5
18. 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 4 FA EN Ver 2 0 22 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 into 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 49 Nilfisk ALTO 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 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 referenc
19. 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 4 FA Technical Data Test Result Tol Tol Test Result Tol Tol Test Result Tol Tol Pump Data Max inlet pressure bar 100 to 41 j Max Inlet temperature C 4 40 4 5 50 5 50 Pressure Cylinder Head bar NEUSS 5 50 Pressure Outlet bar 8 9 3 Q9 5 e N 8 Pressure after Gun bar Pressure cut off Cylinder Head OT bar B 178 192 omo d Pressure Pmax safety valve NM 250 5 5 250 5 5 2 90 Flow Qiec l min 11 55 12 20 13 70 Flow Qmax l min 5 12 50 0 6 13 10 0 7 14 60 07 I 6 50 o rw T Ceramic a mE __ gt ss Lx Oil BP Energol GR XP Oil BP Energol GR XP 220 a 30 125 ofiso
20. motor is switched on Flow sensor fault Contact Nilfisk ALTO Service Water tap closed or water shortage e Cold water operation possible Required volume flow and pressure e Pressure regulation on The safety Turn the twist grip on safety control block or Va control block or VarioPress lance set to rioPress lance1 to higher water volume low Water volume Contact Nilfisk ALTO Service e Machine scaled Plug not connected to the electrical the plug into the electrical socket plug socket e Check fuse Constant light H e Fuel shortage e Top up fuel Cold water operation is possible OU Flashing light 1 Nifisk ALTO AntiStone shortage Top up Nilfisk ALTO AntiStone Constant light e Service interval has expired e Contact Nilfisk ALTO Service Flashing light e Service interval due in 20 hours e Contact Nilfisk ALTO Service Constant light o e Pumpoil low e Top up pump oil Flashing light simultaneously e leakage or inadmissible operating con After three times of short time operation the manchi dition by short time operation ne switches off Reset Turn main switch to position OFF then start again Keep spray gun pressed for longer than 3 seconds If a leak occurs causing the machine to start and stop briefly 3 times then the machine will switch off e Spray gun leaking e Check Spray gun e High pressure hose coupling or line e Replace high pressure hose retighten screw fitti
21. requirements are satisfied the electromotor M1 runs and drives the HP pump for 20 5 bypass mode If the spray device is actuated the HP pump intakes water from the water break tank and conveys it through the by pass valve past the flow housing and the pressure gauge termi nal through the heat exchanger to the spray device The pressure gauge indicates the working pressure NEPTUNE 4 FA EN Ver 2 0 22 11 23 Nilfisk ALTO Function D If the main switch S1 is set to Hot water mode with the spray device open and the required tem perature is subsequently preset with the same switch if the temperature sensor B1 is within set limits if the level sensor B9 signals that there is sufficient fuel in the tank and the flow indicator B2 determines adequate volume flow in the system the processor turns on the burner motor M2 the anti scale pump Y3 and the ignition transformer T2 across the burner relay K2 A high voltage ignition spark is generated on the ignition electrodes in the burner The burner motor M2 blows preheated air through the burner fan into the heat exchanger The self intaking fuel pump conveys fuel under pressure to the solenoid valve Y1 After 1 s of preventilation the solenoid valve Y1 opens and fuel reaches the fuel nozzle In the bur ner it is atomized and ignited The fuel pressure is applied on a line to the dosing device of the anti scaling valve This opens and depending on how it is set
22. rotor to 16mm bolt into the threads Tighten the be kept in the right position in proportion bolt against the motorshaft and pull the to the stator wobble disc out NEPTUNE 4 FA Ver 2 0 22 11 41 Nilfisk ALTO service Repair Why Compromise Bearing system E Fig F 31 Bearing 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 19 33 A amp B n B te Wi Ow di Fig F 32 Bearing track Fig F 33 Bearing track The curved edge A of the bearing tracks The sharpe edge of the bearing track must be mounted against the D bearing must be mounted against the bearings cover and the wobble disc NEPTUNE 4 FA Ver 2 0 22 11 42 Nilfisk ALTO Service Repair Why Compromise D bearing cover Fig F 35 Oil sleeve Fig F 34 D bearing cover The D bearing cover is mounted to the The oil sleeve in the D bearing cover can Motor by four 6mm bolts be demounted carefully 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 carefully push the fan with a screwd
23. 0 00 0 5 05 860 8 60 041 1440 EZ or 3 00 Type DI 4 3 Piston type a SE SE SEE a a Piston diameter mm _ 20 2 2 Stroke Wobblediscange 61 81 f 102 Oil BP Energol GR XP Oil BP Energol GR XP Oil BP Energol GR XP Pump oil type 220 220 Oil volume 1 Electronics Elec V Ph Hz EN AN Current consump hot A Current consump cold A 446 455 _ 30 Power Consumption hot KW hot 3 5 0 5 0 5 3 6 0 5 0 5 EE e nex Fuse size A 108 16 _ n VCT Cord type HO7RN F 4G1 5 x 6m HO7RN F 3G1 5 x 6m 5x6m Plug type CEE 3P N G 16A CEE3P N G 16A Control qm a Control voltage 24 Volt Controlvoltage 24 Volt Control voltage 24 Volt Controlvoltage _ Contactor 100 C12KJ10 5 5kW 100 C12KJ10 5 5KW 100 C3024V 50 00H Electrical diagram 106421531 106427175 106421532 Eletrical test data Highvoltage HV test V 1000vae dve 100vVec HV Resistance MQ 2z1MQ 50Vdc z1MQ 50Vdc z1MO 50Vdc 020 _____ 020 Cord resistance Ohm Motor Data __ tInduction te Induction Induction gt wo 15 16 J CasF ChasF
24. 30 ad PP bar 27 5 5 27 5 5 27 5 5 Fuel pump type eea f Dee Dee Oil pressure bar L posn o 1 _ pos o 12 posi o Nozzle size oi __ s son 112560 61659 CO content min o bosd of 105 050 o _ 105 os Efficiency burner 26 92 sos X 92 45 05 Soot picture j _ Exhaust outlet temperature C o ___ to 460 00 160 0 Exhaust temperature cut off Pam ___ 42 270 wor 42 270 ss 42 Fuel consump dT 45 deg kg h a foo fort 42 00 01 32 o ot Fuel consumption kan 12 sz sr o0 o0 s2 oo Water volume in coil Lo 34 834 34 Fuel tank GT sma Others Gun SrERGO200 STERGO2000 200 sk Lance 920 920 940 Hose 3 8 DN KT NM High pressure nozzle 055 NT 0550 NT NTO550 NT NTO400 Noise level 1m Lpa dBA L m Casas me ET Noisepower LWA dB A 9 fess __ 92 j5 5 4 stas Impact force es 1 Vibration ISO 5349 m s Protection Class x fipxsiipxs iPx PPXs PX5 5 5 Max detergent flow from full internal tank 96 tala 4 leal adea Max detergent flow from full internal tank L min 0 58 0 2 0 2 0 58 0 2 0 2 44 an 2 2 Approved by ee TT Approvals tiia s
25. 5 Jwala e Jafa z ui 4 To nini PN P PR gun C 30 0 3 30 0 3 30 2 3 SM a als x sec 30 5 5 0 5 5 a steamnozzle C 140 10 30 10 30 10 30 Pressure P2 outlet v standard nozzle er PE slg m bar 5 5 5 5 5 5 Fuel pump type Desi Dee Oil pressure bar p05 0 n2 pO5 0 __ 144 __ 08 Nozzle size oi 1256vH 11 2560 61659 125608 CO2 content min 105 sos o _ 105 050 of _ 105 05 0 Efficiency burner 9 sj 05 _ 9 15105 _ 92 4151 05 Soot picture Exhaust outlet temperature C __ do faofao 145 ___ 160 ___ 10 Exhaust temperature cut off C z Jfa __ 270 forfa 270 sor 42 Fuel consump dT 45 deg kg h a 00 01 foo for 42 100104 Fuel consumption g 12 cinlet 87 ooloo s2 foofoo s7 0000 Water volume in coil 34 34 J 34 Fuel tank as 5 ___15 as _ 15 ts 15 Others Gun ST ERGO 2000 mn ST ERGO 2000 EBENE ST ERGO 2000 TORNADO PLUS UNIVERSAL PLUS TORNADO PLUS Lance m 7 Hose DN DN8xt m DN DN8x15m x 15m DN DN8d5m High pressure nozzle mam e Noise level 1m Lpa dBA ze silts __ 50 5 51 15 Noisepower LWA dB A ve Impact force e T
26. Current consump hot 223 122 __ 10 30 Current consump cold A 235 127 1 0 30 RIENI Power Consumption hot kW hot 5 8 6 0 5 0 5 0 5 Fuse size A 246 ___ TT Cord type Tee Plug type L EET 16A Schuko GEESPHN G 16A gt Contro pg P pg Control voltage 24 Volt Control voltage 124 Volt Control voltage 24 Contactor 100 012KJ105 5kW 100 C12KJ105 5kW 100 012KJ1055W _ Electrical diagram ______106427474 106427170 30427270 gt Eletrical test data _ Highvoltage HV test V dove 100 gt HV Resistance __ 21ma soovdc 1mQ s00vde 21Ma s00vdc gt induction induction Induction _ 10 w 4 _ gt 094 PB mn _ O 988 j 4 j LP 85 J o5 os os Cord resistance Ohm Motor Data NEPTUNE 4 FA EN Ver 2 0 22 11 17 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Test Result Tol Tol Test Result Tol Tol Heating Unit a a j 6 Temperature t max inlet 12 C 7
27. JETY y 42214 ES HJEIY ms HE10 200719 19 dund aje15J0y EA 16 L uni pun ELX ILX Juin SUE il Jaume bl 14 15 Ja ir JE LO JE JH ue saung eld JRO TH 0422407 I3 Je Bupjug ys i 464122427 ung H qan YIJIMS JED 3 59 31045 HUB JEG d 495495 FE 19 16 dwnd 13415 JED 4 gu dua 1 4 amp 5 dpj5 4 J id 195495 E upei Ev 4871044 2 008 L38 3 LY qan 94045 JU qp dung 61 NEPTUNE 4 FA EN Ver 2 0 22 11 Notes NEPTUNE 4 FA EN 2 0 22 11 62
28. NEPTUNE 4 FA Service Manual Nilfisk ALTO Why Compromise Nilfisk ALTO Item nr 107146560 Version 02 22 201 1 Nilfisk ALTO Preface Why Compromise This service manual contains detailed description of the main repair work on the hot HPW NEPTUNE 4 FA Repair work requires a suitable testing workplace with the necessary water and power sup ply 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 Technical Service Bulletin TSB sheets Previously called Service Technical Information STI They include information on technical modifications that have been made after this repair manual was printed Technical Service Bulletin sheets are also valid as a supplement to the spare parts list until publication of a new edition Repair manuals and 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 FA EN Ver 2 0 22 11 Nilfisk ALTO Index Why Compromise Safety Instructions 4 DEB 5 Construct
29. UDI 2140442913 d E121 H 126601720 Jan 94945 19 09491300 T TT aT ag aT NEPTUNE 4 FA EN Ver 2 0 22 11 Nilfisk ALTO Why Compromise d iring gt Sen A TEE ADEE ak P M ak 3 EE ew p WH BBY me TELLE DAL souenpy ER ras er B UE 28 Buipuoonoo DM TN ATS agn 991 8002 TdH 1907246 ud vj yoa SH 91 50 eu x pd 7 2142919 ma see sunduan jang aways TX dung 8 42219 jpg L 43219 GO Ger 9 H329 5 E19 5 43819 o Tag JE ae Y er 289 i i 0 is 12 J T AJD18 TYNIASIL dwund aje35i4um dund LA gt n l 5 P LL al ss YI AG 2190 1615 zs pepe n i Lam ej TL m Ela EN mus t m 1 mm a 5n 201 24915 LEO 195185 LH po diund 414195 48014 gg U31185 duia 1 Hx3 qapas LIE JS H Jd JEIPUI 495425 LB 2213 Ly E
30. Y O HO7RN F4G1 5x6m HO7RN F4G15x6m T CEE3PSNGIT0A m To 100 C12KJ1055kW 100C12KMO55kW ___ _ 106427175 406427170 1000v ve gt tmavsoovec gt demde induction gt o w wo eek lass 15 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Test Result Tol Heating Unit Boilerpower input KW Boiler on time at 50 C set point inlet 12 sec 5 451 5 451 Steam temperature outlet and v steamnozzle C P To PTS zer Pressure P2 outlet v standard nozzle bar 5 roe EP Fuel pump type Oil pressure pa fofo 1 1050 o Nozzle size oi 12580 gt CO2 content min 405 os 0 wos 1050 o Efficiency burner s 45 05 92 15 08 Soot picture __ __ ua MS stor _____160 ____ 40 Exhaust temperature cut off ____ m wf Fuel consump dT 45 deg kg h 28 foo __ 40 Fuel consumption kg h 12 C inlet MN Exhaust outlet temperature C a Water volume in coil I Fuel tank I Others Gun _ SrERGO200 stercozooo Lance UNIVERSALPLUS940
31. Z ml 56 NEPTUNE 4 FA EN Ver 2 0 22 11 dun d ard HH um IB CER LL Wiring diagrams Thy pam 1 IBU LAE JETH JE JET Te dnd ups MIU AU AUS Nilfisk ALTO Why Compromise UTAH ud 74 ugJbelp 11411813 JE et ota met 4 Jed ML NR paon 25 a hes mag PE 5 seg IAY EEE XH i PE z ENE IH AT m a E es Ley SI NEPTUNE 4 FA EN Ver 2 0 22 11 Nilfisk ALTO Why Compromise d iagrams iring mi F mz roads jouapoy 0 01 90 zm 49 30 meuna PH yrs 0 ipu fe AMS menna 7 61167901 1210440 dund ajeasyuy EK dund 110 LA uad ELX LUX sue tl LL HI UD 15 JOLOW 07241940 1M 9 49 UE J 9 JD LU LM 48122449 493195 aule iu 2 5 way 1 LILIMS 401524415 i Md zu 195125 LE 192 4197 100242913 LY
32. ahco 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 4 2 0 22 11 39 Nilfisk ALTO oervice Repair Replacement of secondary seals and header rin Fig F 25 Damaged header ring NEPTUNE 4 FA EN Ver 2 0 22 11 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 will block pistons and valves in the pump or get stucked in the non return valve in the unloa der 40 Nilfisk ALTO Service Repair Why Compromise Wobble disc Fig F 26 Pump head The cylinder head and the cylinder block Overview of the parts inside the D Is fastend to the D bearing cover by two bearing cover 6mm mounting bolts for the cylinder block and three 12mm bolts for the cylinder head V Fig F 28 Wobble disc Fig F 29 Wobble disc removal The center bolt is fixing the wobble disc Demount the wobble disc screwing a to the motor shaft and ensure the
33. alve at cleaning agent inlet e Remove suction valve and clean or replace soiled Burner soots e Fuel contamination e Contact Alto Service BEEN Burner sooted or adjustment incorrect Contact Alto Service NEPTUNE 4 FA EN Ver 2 0 22 11 22 Nilfisk ALTO Troubleshooting Why Compromise Boiler performance The symptom is reduced performance of the pump effect or the boiler effect The symptom of reduced 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 Sooted boiler tube e Air deficiency e Check air adjustment and fan at Soot has the same effect as scale depo tachment to boiler sits i e that they are both insulating against the heat transfer to the water e Bad oil air mixture e Check oil pressure and oil quality Replace the oil nozzle Adjust air and results in increased flue gas tempe diffuser rature increased flue gas loss Other symptoms are that the machine Unfinished combustion e Check bottom insulation boiler top smokes during steady operation gasket between tube and inner boiler jacket in top cover e Check burner tube Unstable ignition Check electrodes Adjust the air quantity less air Leaky solenoid valve on pump Check replace solenoid
34. bustion is needed the fuel goes back to the tank on the return line 9 The ignition transformer 10 activated in Hot water mode generates ignition sparks across the electrodes 11 to ignite the fuel soray This process is monitored by the flame sensor 12 if installed and activated In normal operation the hot exhaust flows downwards and upwards between the piping of the heating coil 4 thus warming the water in the system The exhaust exits through the chimney 13 1 Burner fan 2 Air distributor 3 Fuel nozzle 4 Heating coil 5 Fuel pump 6 Fuel filter 7 Solenoid valve 8 Fuel nozzle holder 9 Fuel return line 10 Ignition transformer 11 Ignition electrodes 12 Flame sensor optional 13 Chimney ie Flame tube 5 Flame funnel 6 Insulation 7 Water inlet 8 Water outlet Fig D 2 Hot water function NEPTUNE 4 FA EN Ver 2 0 22 11 25 Nilfisk ALTO Function D ee a ae 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 senses 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 gt 270 C 518 will switch off if the burner keeps burning without water flow through the boiler The safety thermal switch must be reset manually in the electrical box B4 Flo
35. conducts anti scaling concentrate into the water break tank The setting of the dosing device is a function of water hardness The flame sensor B7 if installed and activated checks whether the fuel air mixture is ignited and allows the burner to continue running If there is no flame 4 s after starting Hot water mode the solenoid valve closes and the burner is turned off without postventilation Depending on the setting of the SDR valve selection dosing and rinsing the high pressure pump intakes detergent Detergent alone is only drawn in by the foot valve in the maximum setting Other wise the volume drawn by the pump is a water detergent mixture NEPTUNE 4 FA EN Ver 2 0 22 11 24 Nilfisk ALTO Function D The heat exchanger is the functional link between the heating subsystem and the water subsystem In Hot water mode the burner fan 1 draws in air and conducts It laterally into the heat exchanger where it is routed upwards between the two jackets to the air distributor 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 possible any condensation on the surface 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 fuel nozzle holder 8 with the fuel nozzle 3 If no com
36. ction valve B Rotor F Pressure valve C Wobble disc BY pass housing D Ceramic piston H Water regulation valve The three ceramic pistons D are driven by 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 disc C decides the volume of water which is sucked through the suction valves E and pressed out through the pressure valves F 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 4 FA EN Ver 2 0 22 11 27 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 A into the by pass housing C The water runs through the bottom of by pass housing C 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 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
37. e 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 mea sures 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 specified values are obtained 5 Finally seal the set screw arrow A of the air flap with varnish Fig G 15 Fuel pressure setting Fig G 16 Air flap Mount pressure gauge on the fuel pump 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 in take turning counterclockwise reduces it NEPTUNE 4 FA Ver 2 0 22 11 50 Nilfisk ALTO 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 NEPTUNE 4 FA Ver 2 0 22 11 Fig G 18 Burner measurements The CO2 content
38. ed in chapter G Electrical diagrams can be found in chapter H E E m Hl B1 B2 MT 4 24 B3 209 1 37938 01001231 100 03 03 Data logger Ki Y1 8VAC Fig C 7 PCB Hour Display setting Bypass time canceling NEPTUNE 4 Ver 2 0 22 11 20 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 superheating Flame sensor Electrodes Fuel nozzle Exhaust Water outlet Top plate Water inlet Air distribu L m Flame tube top part re Pr Flame tube E 4 Fig C 8 Boiler N NEPTUNE 4 FA EN Ver 2 0 22 11 21 Burner tube Fixation spacer Outer jacket Inner jacket ee r B AL X EM m m Cae RAO O W I ee ul ul n s 5 al n a ul k CET a Fie Ta r Meme m TIR a Vee IE 5 LI IL nr Tr LA ETa 8 Mounting plate Nilfisk ALTO Construction Why Compromise
39. et 12 C m faar 4 Fe gun C 30 0 3 30 2 1 3 30 2 3 dd Do aral s ada sec 30 5 5 30 5 5 30 5 5 e steamnozzle C 10 30 10 30 10 30 2 outei standard nozza a a pela bar 5 5 5 Fuel pump type Diesel Diese Oil pressure bar mama um a Nozzle size 426 15 CO2 content min _ o _ 105 _ _ 105 hos 0 Efficiency burner 92 fet silos 92 ju5 05 _ 92 15 05 Soot picture or jJ l _ Exhaust outlet temperature C __ ww aoao e10 10 160 0 40_ Exhaust temperature cut off C x rz 270 a 270 40 442 Fuel consump dT 45 deg kg h 40o 00 for 40 00 01 40 oo ot Fuel consumption kg 12 Cinet 52 oo oo __57 _ oo oo sr Water volume in a a 34 j Fuel tank as 15 1515115 15115 15 Others Gun ____ sterco2000 sterco2000 sterGO2000 roses omne mmus Lance 920 920 920 Hose 3 8 DN ET 3 8 High pressure nozzle NTOOO NT 0500 NT 0500 0500 5 Noise level 1m Lpa dBA Noisepower LWA dB A 77 7 1 fed 7 TT Impact force al a
40. hines capacitor might still be charged Fig F 06 E box knob disassembly e Loosen the screw in the bottom of the knob 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 4 FA Ver 2 0 22 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 35 Nilfisk ALTO Service Repair Why Compromise By pass system Fig F 10 By pass valve cone By reassembling 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 4 FA Ver 2 0 22 11 36 Nilfisk ALTO Service Repair 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 hous
41. 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 air flap Fig G 06 a little and check the soot rating and Co2 content again 51 Nilfisk ALTO Adjustment Test Electronic settings 1 BRI 2 BR2 3 X5 4 Fuel LED 5 Anti Scale LED 6 Service LED 7 Pump oil LED 8 Operation LED 9 Service jumper 301001873 Fig G 20 Electronic adjustment setting possibilities 1 this can be used to eliminate the pump bypass time of 20 seconds With jumper bypass time active Without jumper bypass time eliminated BR2 2 this can be used to activate the optional flame probe Jumper on 1 2 flame probe inactive Jumper on 2 8 flame probe active X5 3 the data logger is connected here for readout of operating data X5 is also im portant for setting the service interval Service interval settings Switch off the machine with S1 Place a wire jumper 9 between pins 3 and 5 on X5 owitch on the machine Cold water mode By temperature setting it is now possible to set a new service interval read from the status display LEDs 4 8 beginning with the Fuel LED 4 each LED stands for 100 h producing a setting range of 100 to 500 h in 100 h increments If the setting is not a
42. ing Carefully tip out the sleeves with an adequate screwdriver and replace them Be careful not to scratch the surface NEPTUNE 4 FA Ver 2 0 22 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 with an 8 10mm mandrel to demount and pull it out Replace with new parts 22 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 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 4 2 0 22 11 38 Nilfisk ALTO Service Repair 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 the cylinder block adequate puller Be careful not to damage the surface of the cylinder block Puller used in the picture is B
43. ion ainaani 17 S IC YVI ee re 17 TOD WIG 17 Frame and 18 Operation panel 19 Panel Iinside 19 Electrical DOX qe EEE EE 19 PEB A EC _ 20 er eee 21 Motor Pump Ur 22 SN 22 FONN 22 FUNCIO P nen 23 DEN 23 Hot water function 25 Sensors and actors 26 Me UNN 27 Working pressure 28 By pass pressure 28 Water reduction 29 mie TIE 30 Troublesnoollhg u uu u u uu aE 31 Boiler performance 33 Service Repair tcn 34 u uuu uu 34 Oil maintenance a 34 FAE 34 Electrical system Maintenance 35 By pass system 36 NIV 37 Gale 9 5 3 GENUS EE 39 Wobble disc system
44. isk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Tol Tol Test Result Tol Tol Test Result Tol Tol Heating Unit Boilerpower input KW 6 e J Temperature t max inlet 12 C 8 Jafa re ala 76 Jaa Fe fola POP o lafa gun C 30 0 3 30 0 3 30 2 3 ET 0 3 0 3 5 5 MM steamnozzle C 10 30 10 10 bar 5 5 5 Fuel pump type Diesel Diesel Dee Oil pressure bar kas ka Nozzle size oil 112560 61659 12560 12500H CO2 content min 4051 ol 105 050 105 05 0 Efficiency burner aM 92 0 5 92 0 5 92 J451 05 Soot picture au ma j Exhaust outlet temperature C ___ to 460 1 0 40 160 e10 10 Exhaust temperature cut off C _______ 270 30 42 270 2 20 30 42 Fuel consump dT 45 deg kg h e 61 26 92181 s0 ton for Fuel consumption 12 s2 o0 00 s _ 00 00 Water volume in coil 3 T ee TT Fuel tank D _____ 5 ___15 5 _ 15 as as _ 15 15 1 Others Gun STERGO200 SrERGO200 sterco2000 pesas peemeep uma Lance 940 940 920 oss onsen PM ed H
45. ltered for 3 s the value is assumed indica ted by flashing of the set LEDs The machine must then be switched off by S1 and the wire jumper removed from X5 The default ex works is 200 h NEPTUNE 4 FA EN Ver 2 0 22 11 52 Wiring diagrams Nilfisk ALTO Why Compromise wang IH ud paraat I gt _ ee Bi TT 53 NEPTUNE 4 FA EN Ver 2 0 22 11 Nilfisk ALTO Why Compromise d iring iagrams T 194164 Aqpuaeg 209 EN J amp muimu Eun mz lars JES YTE WEJHEID 21242913 42219 OO pe Bop E e Oe spe ope ee 41219 9 42214 5 42214 4 PENG H3210 H3219 A2010 TAHYI dund aps jug dun 10 ur J 9438 8 9 eiat WE JAUN 2040 uaa AS m asn 4 24 14 H yan 3115 JED d aua Js WUE 5 JEG 4 16999 dund 42 195 9045 45 210442813 i gt Loe oo ee n y cqA gt
46. m pump Non return valve magnet piston for H H Reed switch for start of heating system Water outlet 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 0 Machine started 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 gun 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 4 FA EN Ver 2 0 22 11 30 Nilfisk ALTO Troubleshooting Why Compromise Indication lights Cause Remedy The appliance is ready for operation When switching on all the LEDs light up once before the
47. n 16 O NEPTUNE 4 2 0 22 11 14 Nilfisk ALTO Why Compromise NEPTUNE 4 FA Technical Data Pump Data Max inlet pressure bar Max Inlet temperature C Pressure at pump head Pressure Cylinder Head bar Pressure Outlet bar Pressure after Gun bar Pressure cut off Cylinder Head bar Pressure Pmax safety valve Flow Qiec l min Flow Qmax l min Flow Qmin steam l min Type Piston type Piston diameter mm Stroke Wobble disc angle Pump oil type Oil volume 1 Electronics Elec V Ph Hz Current consump hot A Current consump cold A Power Consumption hot kW hot Fuse size A Cord type Plug type Control Control voltage Contactor Electrical diagram Eletrical test data Highvoltage HV test V HV Resistance MQ Cord resistance Ohm Motor Data NEPTUNE 4 FA EN Ver 2 0 22 11 Technical data Test Result Tol Tol Test Result Tol Tol 5 50 _____ 105 ____ 6 6 _____ 184 f 10 10 550 86 ______ 5 6 144 f 8 8 em att 1 180 ____ 5 EX 5 Eg ____ me j _ erme gt EP 102 2 NEN HN BP Bas GR XP Oil BP Energol GR XP 220 220 240vm r0r2 50 30 30 _ 45 126 410 30 27 fos 05 ____ 61 05 05 o oas lt
48. ngs system leaking e Detergent tank empty e Top up detergent tank or set detergent metering to OFF e Waiter inlet filter dirty e Clean filter e High pressure pump drawing in air e Repair leaks NEPTUNE 4 2 0 22 11 3l Nilfisk ALTO Troubleshooting Why Compromise Indication lights Cause Remedy Flashing light alternately e Motor overheated e Turn main switch in position OFF let the machi ne cool down Remove disconnect extension cable Possible phase failure have electrical connection checked e Machine overheated e Contact Nilfisk ALTO Service Flashing light e Flame sensor sooted Clean flame sensor e Ignition or fuel system failure Contact Nilfisk ALTO Service Cold water operation possible au ___ eae Pressure too low e High pressure nozzle worn out e Replace nozzle Pressure regulation set to low pressure ore Turn the twist grip on safety control block VarioPress lance set to low water vol clockwise or set VarioPress lance to ume higher water volume Machine is running with e Pump has drawn in air as the detergent Close detergent valve Remove lance from pulsating pressure and tank is empty gun Operate spray gun and let machine run makes knocking noise until air in pump is gone and the machine is running normally calm again No detergents drawn in Detergent tank empty Top up detergent tank Pe Dirt in detergent tank e Clean detergent tank Suction v
49. olume I 005 05 096 Electronics Elec V Ph Hz Current consump hot A 168 molao 123 10 30 122 223 10 3 0 Current consump coa Ap 175 126 ___ 125 23 10 3 0 MP even hot 4 7 0 5 0 5 6 1 0 5 1 0 5 6 5 8 0 5 0 5 Fuse size A ___ 2 1 1 w 2 _ 7 85 frome acesson _ Cord type 4x3 5x6m HO7RN F 4G1 5 x 6m HO7RN F 4G2 5 x 6m Plug type _______________ 6 Contro Control voltage 24 Volt Controlvoltage 24 Volt Control voltage 24 Volt Controlvoltage _ Contactor _ 100 30 24 50 60 100 C12KJ105 5 W 100 C12KJ1055KW _ Electrical diagram 106421532 1 106427170 Eletrical test data Highvoltage HV test V __ 1000vae dove 100 HV Resistance MQ __ z1MQ 50Vdc z1MQ 50Vdc z1MO 50Vdc S 020 020 Cord resistance Ohm Motor Data S idution Induction 3 Induction wo 15 10 J CasF ChasF NEPTUNE 4 FA EN Ver 2 0 22 11 9 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 Technical Data Test Result Tol Tol Test Result Tol Tol Test Result Tol Tol Heating Unit Boilerpower input KW a 6 j _ Temperature t max inl
50. ose DN 8 x 15m DN 8 x 15m 3 8 High pressure nozzle NT 0460 NT 045 0500 Noise level 1m Lpa dBA ale Noisepower LWA dB A 9 fess 9 jusn t5 9t stas Impact force 3 45 _ Vibration ISO 5349 m s Protection Class px Jexslexs PxsiPxo 1PX5 iP x5 IP x5 Max detergent flow from full internal tank tv aa Teal gt Max detergent flow from full internal tank L min P gem Approved by SLG Chemnitz Chemnitz SLG Chemnitz Chemnitz SLG Chemnitz Chemnitz Approvals BREL P DE ee NEPTUNE 4 2 0 22 11 6 Nilfisk ALTO Technical data Why Compromise NEPTUNE 4 FA Tol Tol Test Result Tol Tol Test Result Tol Tol Technical Data Test Result Pump Data Max inlet pressure bar ___ 10 10 EN Max Inlet temperature C 40 gt NN 5 50 5 50 Pressure Cylinder Head bar 105 6 Pm 133 7 162 9 m 5 50 Pressure Out ba al w hels mw lafla ow Pe 5 50 pressure atter a ps s nmo ___ 6 12 5 as ta less bar 125 5 5 140 5 5 182 5 5 Pressure Pmax safety vave 180 s5 5 210 5 __ 250 __ 5 5 2 90 row min _ pos os _ 02 02 Flow Qmax I min 1
51. river NEPTUNE 4 FA Ver 2 0 22 11 43 Nilfisk ALTO service Repair Why Compromise Fuel tank Heating system Fig F 38 Fuel tank Overview 1 Fuel tank 2 Strainer 3 Float valve 4 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 Fig F 40 Fuel nozzle Fig F 41 Fuel nozzle NEPTUNE 4 FA Ver 2 0 22 11 AA Nilfisk ALTO oervice Repair Exhaust temperature sensor Fig F 42 Temperatur sensor e The exhaust temperature 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 Fig F 44 Burner unit NEPTUNE 4 FA EN Ver 2 0 22 11 45 Nilfisk ALTO Why Compromise oervice 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 46 Dismounting coil Attention Be aware of the fact that the machi ne can tip over Keep the coil close to the ma chine Fig F 47 Dismounting coil
52. romener lade sec 30 5 5 30 5 5 30 5 5 meses e auja a steamnozzle C 10 30 10 1 30 10 30 PP PSP bar 5 5 5 Fuel pump type Diesel Oil pressure bar Sa el e uix Nozzle size oi 428608 125608 2 content min 0 105 405 o _ 105 3051 ol Efficiency burner 9 i5 05 92 415105 92 151 05 Soot picture x ot LL Exhaust outlet temperature C __ wo 160 ftv 40 160 10 410 Exhaust temperature cut off C aM 2 0 2 0 2 0 Fuel consump dT 45 deg kgih gt 4o __ 42 __ 42 __ Fuel consumption kgh i2 C inet 57 oo oo 57 _ o00 00 sz 00 00 Water volume in coil 34 34 34 Fuel tank D ts 15 5 15 RE Others Gun STERGO200 sterco2000 sterco2000 T Lance 920 920 920 I Aer owe Hose DN 8x15m 3 8 DN ETE High pressure nozzle NT NTo500 NT NTO0500 Noise level 1m Lpa dBA Lui ala Noisepower LWA dB A onl a a a Impact force N T e 1 1 4 Vibration ISO 5349 m s Protection Class te xs PXS PXS xs IPX PX Max detergent flow from full internal tank 1 4 PHEB PETER Max detergent flow from full internal tank L min 0 55 E s ma HE
53. valve Y1 Y1 Low oil pressure e Incorrect adjustment e Adjust pump pressure see page 45 Filter blocked defective pump Replace filter oump Empty and clean tank Full water quantity at steam stage e Mechanical defect of by pass e Check by pass valve valve or adjustment NEPTUNE 4 2 0 22 11 33 Nilfisk ALTO oervice Repair Observations 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 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 4 FA EN Ver 2 0 22 11 34 Nilfisk ALTO Why Compromise oervice 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 screws shown in the red circles e Caution On 1 mac
54. w 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 C 320 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 solenoid 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 4 FA EN Ver 2 0 22 11 26 Nilfisk ALTO Function D Fig D 4 Motor pump A Stator E Su
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