Nilfisk-ALTO Neptune 4, NEPTUNE 4-54, NEPTUNE 4-49, NEPTUNE 4-42, NEPTUNE 4-30 Service Manual

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NEPTUNE 4

Supplement to Service Manual NEPTUNE 3 and NEPTUNE 5 / 7

A. Safety instructions

B. Technical data

C. Construction

D. Function

E. Troubleshooting

F. Maintenance / repair

G. Adjustments

H. Wiring diagrams

I. Special tools / spare parts

Nilfisk ALTO

Index

Preface

A. Safety instructions

B. Technical data

C. Construction

D. Function

E. Troubleshooting

F. Maintenance / repair

Notes

1. NEPTUNE 4-25 / NEPTUNE 4-28

2. 4-30

3. N 4-42

4. 4-49

5. 4-54

... 1

... 2

... 3 ... 4 ... 5 ... 6 ... 7

... 8

... 9

... 10

... 11

... 19

NEPTUNE

EPTUNE NEPTUNE NEPTUNE

G. Adjustments

H. Wiring diagrams

I. Special tools / spare parts

... 12

... 13 ... 14 ... 15 ... 16

... 18

1. Wiring diagram parts list

2. 3~ star (71305)

3. 3~ star / delta (71306)

4. 1~ with Klixon relay (71307a)

5. 1~ with starting electronic (71418) ... 17

Index

Neptune 4_EN_Ver.1.0_04/06

Nilfisk ALTO

There are only minor differences between the NEPTUNE 4 hot-water high-pressure cleaner and NEPTUNE 3 and NEPTUNE 5 line of products. This service manual mainly refers to the concerning sections in the service manuals NEPTUNE 3 and NEPTUNE 5

Repair work requires a suitable testing workplace with the necessary power supply.

If operating errors are evident, refer the customer to the user manual.

A fault in the cleaner can have a number of causes. Refer to Chapter E for troubleshooting.

Also refer to the illustrated spare parts list (p

301002627) for your repairs. This shows you the location of the individual parts and the sequence in which they are assembled.

Read the ”Service / Technical Information” sheets. They include information on technical modifications that have been made after this service manualwas printed.

”Service / Technical Information” sheets are also valid as a supplement to the spare parts list until a new edition is published.

Service manuals and “Service / Technical Information” sheets should be available at the place where repairs are carried out.

Transfer to third parties is not allowed.

Use original spare parts only!

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Preface

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Preface

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Safety instructions

For your own safety

Repairs should only be made by someone who has received proper instructions for the job or who is a qualified electrician.

Observe national safety directives and regulations for the electrical engineering trade, in particular:

IEC 60335-2-69 EN 60335-2-69

Before starting the equipment, be sure to read the accompanying operator manual, and keep it close as ready reference.

The equipment should only be used by persons who have been instructed in its use and are authorized to do so.

ESD (electrostatic discharge)

Observe the following ESD precautions before any repair of or near electronic parts:

Touch the protective conductor to discharge your own body.

Possibly wear an anti-static wrist strap.

Use a conducting floor or tabletop.

Never touch a circuit board or electronic components always hold

it by the plastic or insulation.

Transport electronic parts in conductive packaging (e.g. special

ESD packages).

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Safety instructions

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Table B.1: Neptune 4-25 / Neptune 4-28

1. NEPTUNE 4-25 / NEPTUNE 4-28

Neptune Neptune

4-25 4-28

*GB* *GB*

Machine protection category IP X5 X5 Current consumption A 30 13 Voltage V 110 230 Frequency Hz 50 50 Connected load kW 3 3 Sound pressure dB (A) 72,4 72,4 HP nozzle 500 640 Pressure P1 / P1 max. bar 90 / 200 90 / 200 Pressure P2 / P2 max. bar 25 / 32 25 / 32 Max. recoil force N 25 27 W ater throughput (max.) l/h 720 770 W ater throughput (EN 60335-2-79) l/h 660 720 W ater intake pressure (max.) bar 10 10 W ater intake temperature (max.) °C 40 40

Voltage V 110 230 Frequency Hz 50 50 Connected load kW 2 2,2 Motor insulation CL. F CL. F Ingress protection IP 54 54 RPM U/min 1450 1450

Type NP5 10.12 NP5 11.14 Plunger ceramic ceramic Plunger diameter mm 18 18 Plunger stroke mm 9,8 10,8 Pump oil SAE 15 W 40 SAE 15 W 40 Amount of oil ml 1000 1000

Fuel pressure bar 15 (- 0,5) 15 (- 0,5) Fuel consumption dt = 45 K kg/h 3,2 3,5 Exhaust temperature °C 185 185

content (min.)

% 10,5 (+ 0,5) 10,5 (+ 0,5)

Soot rating 0 - 1 0 - 1 Efficiency % > 92 > 92 W ater content (coil) l 3,5 3,5 Heating power kW 55 55

Length mm 1053 1053 W idth mm 685 685 Height mm 750 750 W eight kg 128 128

High-pressure hose DN 8 x 10 m DN 8 x 10 m Electrical lead m 5 5 Fuel tank l 16 16 Detergent tank l 10 10

Heat exchanger

Dimen-

sions and

weight

Miscella-

neous

NEPTUNE 4

Technical machine dataMot orPump

Note: Neptune 4-28 *GB* is also available as X-model.

Technical data

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Table B.2: Neptune 4-30

Note: Neptune 4-30 *EU* and Neptune 4-30 *EXP* are also available as X-models.

2. NEPTUNE 4-30

Neptune Neptune

4-30 4-30

*EU* *EXP*

Machine protection category IP X5 X5 Current consumption A 15,6 15 Voltage V 230 220 Frequency Hz 50 60 Connected load kW 3,4 3,3 Sound pressure dB (A) 72,4 72,4 HP nozzle 530 500 Pressure P1 / P1 max. bar 110 / 200 105 / 200 Pressure P2 / P2 max. bar 25 / 32 25 / 32 Max. recoil force N 30 27 W ater throughput (max.) l/h 750 720 W ater throughput (EN 60335-2-79) l/h 700 670 W ater intake pressure (max.) bar 10 10 W ater intake temperature (max.) °C 40 40

Voltage V 230 220 Frequency Hz 50 60 Connected load kW 2,2 2,2 Motor insulation CL. F CL. F Ingress protection IP 54 54 RPM U/min 1450 1750

Type NP5 11.14 NP5 2,8G22 Plunger ceramic ceramic Plunger diameter mm 18 18 Plunger stroke mm 10,8 8,5 Pump oil SAE 15 W 40 SAE 15 W 40 Amount of oil ml 1000 1000

Fuel pressure bar 15 (- 0,5) 15 (- 0,5) Fuel consumption dt = 45 K kg/h 3,45 3,3 Exhaust temperature °C 185 185

content (min.)

% 10,5 (+ 0,5) 10,5 (+ 0,5)

Soot rating 0 - 1 0 - 1 Efficiency % > 92 > 92 W ater content (coil) l 3,5 3,5 Heating power kW 55 55

Length mm 1053 1053 W idth mm 685 685 Height mm 750 750 W eight kg 128 128

High-pressure hose DN 6 x 10 m DN 6 x 10 m Electrical lead m 5 5 Fuel tank l 16 16 Detergent tank l 10 10

Heat exchanger

Dimen-

sions and

weight

Miscella-

neous

NEPTUNE 4

Technical machine dataMot orPump

Technical data

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Table B.3: Neptune 4-42

Note: Neptune 4-42 *EU* is also available as X-model.

3. NEPTUNE 4-42

Neptune

4-42

*EU*

Machine protection category IP X5 Current consumption A 10 Voltage V 400 Frequency Hz 50 Connected load kW 5,6 Sound pressure dB (A) 76,5 HP nozzle 0475 Pressure P1 / P1 max. bar 170 / 250 Pressure P2 / P2 max. bar 25 / 32 M ax. recoil force N 43 W ater throughput (max.) l/h 860 W ater throughput (EN 60335-2-79) l/h 800 W ater intake pressure (m ax.) bar 10 W ater intake temperature (m ax.) °C 40

Voltage V 400 Frequency Hz 50 Connected load kW 4,5 Motor insulation CL. F Ingre ss protection IP 54 RPM U/min 1450

Type NP5 13.20 Plunger ceram ic Plunger diam eter mm 18 Plunger stroke mm 12,8 Pump oil SAE 15 W 40 Am ount of oil ml 1000

Fuel pressure bar 15 (- 0,5) Fuel consumption dt = 45 K kg/h 3,9 Exhaust temperature °C 185

content (min.)

% 10,5 (+ 0,5)

Soot rating 0 - 1 Efficiency % > 9 2 W ater content (coil) l 3,5 Heating power kW 70

Length mm 1053 W idth mm 685 Height mm 750 W eight kg 132,5

H igh-pre ssure hose D N 8 x 10 m Electrical lead m 5 Fuel tank l 16 Detergent tank l 10

Heat exchanger

Di men-

sions and

weight

Mi scella-

neous

NEPTUNE 4

Technical machi ne dataMo t o rPu mp

Technical data

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Table B.4: Neptune 4-49

4. NEPTUNE 4-49

Neptune Neptune

4-49 4-49

*EU* *NO , BE*

Machine protection category IP X5 X5 Current consumption A 12,5 21,7 / 12,5 Voltage V 400 230, 400 Frequency Hz 50 50 Connected load kW 6,9 6,9 Sound pressure dB (A) 76,6 76,6 HP nozzle 0550 0550 Pressure P1 / P1 max. bar 180 / 250 180 / 250 Pressure P2 / P2 max. bar 25 / 32 25 / 32 Max. recoil force N 47 47 W ater throughput (max.) l/h 950 950 W ater throughput (EN 60335-2-79) l/h 900 900 W ater intake pressure (max.) bar 10 10 W ater intake temperature (max.) °C 40 40

Voltage V 400 230, 400 Frequency Hz 50 50 Connected load kW 5,5 5,5 Motor insulation CL. F CL. F Ingress protection IP 54 54 RPM U/min 1450 1450

Type NP5 15.20 NP5 15.20 Plunger ceramic ceramic Plunger diameter mm 18 18 Plunger stroke mm 14,6 14,6 Pump oil SAE 15 W 40 SAE 15 W 40 Amount of oil ml 1000 1000

Fuel pressure bar 15 (- 0,5) 15 (- 0,5) Fuel consumption dt = 45 K kg/h 4,4 4,4 Exhaust temperature °C 185 185

content (min.)

% 10,5 (+ 0,5) 10,5 (+ 0,5)

Soot rating 0 - 1 0 - 1 Efficiency % > 92 > 92 W ater content (coil) l 3,5 3,5 Heating power kW 70 70

Length mm 1053 1053 W idth mm 685 685 Height mm 750 750 W eight kg 137,5 137,5

High-pressure hose D N 8 x 10 m D N 8 x 10 m Electrical lead m 5 5 Fuel tank l 16 16 Detergent tank l 10 10

Heat exchanger

Dimen-

sions and

weight

Miscella-

neous

NEPTUNE 4

Technical machine dataMot orPump

Note: Neptune 4-49 *EU* and Neptune 4-49 *NO, BE* .are also available as X-models

Technical data

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Table B.5: Neptune 4-54

Note: All three Neptune 4-54 variants .are also available as X-models

5. NEPTUNE 4-54

Neptune Neptune Neptune

4-54 4-54 4-54

*EU* *NO, BE* *EXP*

Machine protection category IP X5 X5 X5 Current consumption A 14 24 / 14 22,5 / 14 Voltage V 400 230, 400 220, 460 Frequency Hz 50 50 60 Connected load kW 7,9 7,9 7,9 Sound pressure dB (A) 76,9 76,9 76,9 HP nozzle 0500 0500 0500 Pressure P1 / P1 max. bar 200 / 250 200 / 250 200 / 250 Pressure P2 / P2 max. bar 25 / 32 25 / 32 25 / 32 Max. recoil force N 56 56 52 Water throughput (max.) l/h 1050 1050 1050 Water throughput (EN 60335-2-79) l/h 1000 1000 1000 Water intake pressure (max.) bar 10 10 10 Water intake temperature (max.) °C 40 40 40

Voltage V 400 230, 400 220, 460 Frequency Hz 50 50 60 Connected load kW 5,5 5,5 5,5 Motor insulation CL. F CL. F CL. F Ingress protection IP 54 54 54 RPM U/min 1450 1450 1750

Type NP5 15.20 NP5 15.20 NP5 4G30 Plunger ceramic ceramic ceramic Plungerdiameter mm181818 Plunger stroke mm 14,6 14,6 12 Pump oil SAE 15 W 40 SAE 15 W 40 SAE 15 W 40 Amount of oil ml 1000 1000 1000

Fuel pressure bar 15 (- 0,5) 15 (- 0,5) 15 (- 0,5) Fuel consumption dt = 45 K kg/h 4,9 4,9 4,9 Exhaust temperature °C 185 185 185

content (min.)

% 10,5 (+ 0,5) 10,5 (+ 0,5) 10,5 (+ 0,5)

Sootrating 0-1 0-1 0-1 Efficiency % >92 >92 >92 Water content (coil) l 3,5 3,5 3,5 Heating power kW 70 70 70

Length mm 1053 1053 1053 Width mm 685 685 685 Height mm 750 750 750 Weight kg 137,5 137,5 137,5

High-pressure hose DN 8 x 10 m DN 8 x 10 m DN 8 x 10 m Electrical lead m 5 5 5 Fuel tank l 16 16 16 Detergent tank l 10 10 10

Heat exchanger

Dimen-

sions and

weight

Miscella-

neous

NEPTUNE 4

Technical machine dataMotorPump

Technical data

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Construction

Neptune 4_EN_Ver.1.0_04/06

Construction

The external design of the Neptune 4 hot-water high-pressure cleaner is identical to the Neptune 3 line of products. As far as sensors, control, functionality and electronics are concerned, there are no differences to the Neptune 3 series as well. There are only two differences compared to Neptune 3: The Neptune 4 series has the NP5 hp-pump (1) installed (like the Neptune 5) and the machine is equipped with an additional hydraulic accumulator (2)(see also STI MPW-040). For further details about the construction of the machine, refer to the Neptune 3 and Neptune 5 / 7 Service Manuals (chapter C resp. chapter 3).

Fig. C.1: Neptune 4

Fig. C.2: NP5 pump & Control Safety Block with hydraulic

accumulator

The Neptune 4 HPC is available in following versions:

Neptune 4-25: Neptune 4-28:

1~ 1

The machine comes as standard- (with storage tray for accessories, tools, etc.) or X-model (with hose reel instead of the storage tray). Upgrading with a hose reel is possible.

~ 1~ 3~ 3~ 3~

Neptune 4-30: Neptune 4-42: Neptune 4-49: Neptune 4-54:

Fig. C.1 & C.2:

1.) NP5 hp-pump 2.) Hydraulic accumulator

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There are no functional differences between the Neptune 3 line of products and the Neptune 4 series.

For further details on the subject of function refer to the Neptune 3 Service Manual (chapter D) as well as the user manual of the respective machine. For details about the function of the NP5 hp-pump refer to the Neptune 5 / 7 Service Manual (chapter 4). Further valuable information can be found in the Service / Technical Information (STI) sheets for Neptune 3 / 5 / 7.

Function

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Function

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Based on the same microprocessor control as the Neptune 3 line of products, the Neptune 4 shows the same error codes for verification of the cause of a malfunction of the machine. This also applies to other troubleshooting procedures.

For further details on the subject of troubleshooting refer to the Neptune 3 Service Manual (chapter E) as well as the user manual of the respective machine. For details about troubleshooting the NP5 hp-pump refer to the Neptune 5 / 7 Service Manual (chapter

5). Further valuable information can be found in the Service / Technical Information (STI) sheets for Neptune 3 / 5 / 7.

Troubleshooting

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Maintenance / repair

Maintenance and repair works to be performed on the Neptune 4 are the same as for the Neptune 3 line of products, except the hp-pump. Further details concerning maintenance / repair can be found in the Neptune 3 (chapter F) & Neptune 5/ 7 (chapter 6) Service Manuals as well as in the respective User Manual (part number 301002531).

1. Maintenance

For details refer to theNeptune 3 Service Manual chapter F.1.

2. Periphery

3. Control Safety Block

4. Motor

5. Pump

6. SDR valve

7. Heating subsystem

8. Electrical subsystem

For details refer to theNeptune 3 Service Manual chapter F.2.

For details refer to theNeptune 3 Service Manual chapter F.3.

For details refer to theNeptune 3 (chapter F.4.) and Neptune5 /7 (chapter 6) Service Manual.

For details refer to theNeptune 5 / 7 Service Manual chapter 6.

For details refer to theNeptune 3 Service Manual chapter F.6.

For details refer to theNeptune 3 Service Manual chapter F.7.

For details refer to theNeptune 3 Service Manual chapter F.8.

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Maintenance / repair

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Table G.1: Heat exchanger settings

1. Control board

2. Control Safety Block

3. Heat exchanger system

For adjustment refer to the Neptune 3 Service Manual (chapter G.1).

The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.2) or STI MPW-

030.

The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.3) or STI MPW-005 / STI MPW-028.

Adjustments

content

% 10.5 (+ 0.5)

Fuel pressure bar 15 (- 0.5)

Soot rating 0-1

NEPTUNE

4. Flow control

5. Automatic AntiStone

6. Electrical connection

The adjustment procedure is described in the Neptune 3 Service Manual (chapter G.3).

The parameters for adjustment aredescribed inthe Neptune 3 Service Manual (chapter G.4).

The adjustment of the star / delta switch is described in the Neptune 3 Service Manual (chapter G.5).

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Adjustments

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1. Wiring diagrams parts list

Table H.1: Wiring diagrams parts list for Neptune 4

Note: The components listed in Table H.1 relate to the following Neptune 4 wiring diagrams.

Code Component designation

A1 Control board A3 Starting electronic B1 Temperature sensor B2 Reed switch B3 Thermo fuse B4 Microswitch B6 Float switch, pump oil B7 Flame sensor B8 Float switch, AntiStone B9 Float switch, fuel C1 Capacitor C2 Starting capacitor F1 Pico fuse

F2 / F3 Fine-wire fuse

K1 Contactor K2 Relay

K3 Klixon relay M1 Motor, three-phase M2 Burner fan motor MT Thermal protector R1 Discharge resistor R2 Inrush current limiter

S1 Switch on / off + temperature setting

S2 Switch star / delta

T1 Transformer

T2 Ignition transformer

X1 Flat connector

X2-X4 Terminal block

X5 Plug connector, 5-way, datalogger

X11 – X13 Omnibus terminal

Xma-b Motor connector

Y1 Solenoid valve

Wiring diagrams

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2. 3 star (71305)~

Fig. H.1: Wiring diagram 3 star~

Wiring diagrams

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4. 1 with Klixon relay (71307a)~

Fig. H.3: Wiring diagram 1 with Klixon relay~

Wiring diagrams

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3. 3 star / delta (71306)~

Fig. H.2: Wiring diagram 3 star / delta~

Wiring diagrams

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5. 1 with starting electronic (71418)~

Fig. H.4: Wiring diagram 1 with starting electronic~

Wiring diagrams

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Table I.1: Special tools, spare parts and service accessories

For further details about special tools, spare parts and service accessories, also refer to the Neptune 3 (chapter I) & Neptune 5 / 7 (chapter 9) Service Manuals, the Neptune 4 spare parts list as well as the respective STI sheets.

Special tools / spare parts / service accessories

Part No. Description

Comment

17237

Soot pump with filter paper and soot rating

scale 17238 Filter paper (replacement) 17239 Soot rating scale

17240

meter w ith refill flu id

17241

measurin g flu id

17242 Gas thermometer (pointer) 17243 Measuring case (empty) 17246 Fuel pressure meter 40471 Gas thermometer (LCD) 40472 Exhaust loss calculator 63138 Test bolt

301001873 Jumper also see STI MPW /SPW-008 301000383 Datalogger 301000382 Power supply, Datalogger 230 V / 9 V AC German version 301001804 Support for service crane 301001078 Service crane 301001089 Chimney adapter 301002067 TESTO exhaust air probe also see STI MPW /SPW-011 301001875 TESTO central unit also see STI MPW /SPW-011 301001934 Mounting tool, oil seal for pump shaft 301001935 Mounting tool, oil seal for piston 301001090 Crane eye 301001874 Metratester el. safety check

301000911 Safety valve 3~ machines

62730 Safety valve 1~ machines 63056 Repair kit CSB

301001688 Attachment set: Hose reel 301001146 Kit piston 18 mm 301001148 Kit piston sealing 18 mm 301001150 Kit oil sealing 301001151 Kit support ring 18 mm 301001153 Kit valve (x6) for pump

3812385 Fuse 5 x 20; 6.3A/250V, 'slow' F3 3812625 Fuse 5 x 20; 2.0A/250V, 'slow' F2

41455

Grease (-15 °C to +130 °C), tube 50 g;

foodstuff quality 33397 Loctite 242, bottle 50 ml 33667 Silico n grease, tube 100 g

Stop varnish, commercial

Silicon spray, com m ercial

Copper paste, commercial

Special tools

Spare parts / repair kits

Service accessories

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Special tools / spare parts

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____________________ ____________________ ____________________ ____________________

____________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________ __________________________

Notes

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Notes

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____________________

Notes

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Notes

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____________________

Notes

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Notes

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Nilfisk-ALTO Neptune 4, NEPTUNE 4-54, NEPTUNE 4-49, NEPTUNE 4-42, NEPTUNE 4-30 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual