Nilfisk-ALTO Neptune PE, Neptune DE, NEPTUNE 5-46PE, NEPTUNE 5-54PE, NEPTUNE 7-61PE Service Manual
...
Service Manual
NEPTUNE PE/DE
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Jetwash Direct ltd
A.
B.
C.
D.
E.
F.
G.
H.
Wiring diagrams 72-92
Adjustment / Test 63-71
Service / Repair 42-62
Troubleshooting 38 -41
Function 18 -37
Construction 10 -17
Technical data 6 - 9
Safety instructions 5
Jetwash Direct ltd
Index
3
NEPTUNE PE-DE_en_Ver.1.0_October 2010
A. Safety instructions ...................................................5
B. Technical data...........................................................6
C. Constrution
-Overview Unit: .......................................................... 13
D. Function
-Electrical....................................................................18
-Funktion PCB............................................................24
-Pumps.......................................................................28
-By-pass valves & Unloader…………………………....31
-Flow Switch…………………………………………… ..35
-Heat Exchanger.........................................................36
E. Troubleshooting
-Table .........................................................................38
F. Service / Repair
-NA5 Pump.................................................................42
-C3 Pump ...................................................................48
-NP5 Pump.................................................................54
-Heat Exchanger ........................................................59
-Electrodes .................................................................61
-Maintenance………… ...............................................62
G. Adjustment / Test
-NA5 ...........................................................................63
-C3..............................................................................66
-NP5 ...........................................................................67
-Heat Exchanger.........................................................69
H. Wiring diagrams
- .................................................................................72
Jetwash Direct ltd
NEPTUNE PE-DE_en_Ver.1.0_October 2010
4
This service manual contains detailed description of the main repair work on the Hot
Water High Pressure Washer, NEPTUNE PE—DE.
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 trouble-
shooting.
Refer to the illustrated spare parts lists during repairs. They show the assembly posi-
tion and the sequence in which the individual components should be assembled.
Repair manuals and TSB (Technical Service Bulletin) sheets should be available at
the site where repairs are carried out.
It is not permitted to give them to third parties.
Use original Nilfisk-ALTO spare parts only.
Preface
Jetwash Direct ltd
A
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Safety instructions
5
For your own safety
Before using the cleaner, always read the operating
instructions and keep them
readily available.
The high-pressure cleaner
should only be used by authorized persons who have been
instructed in its use.
Although extremely easy to
operate, children should not
be allowed to use the cleaner.
Repair work should be carried
out by persons instructed and
trained in repairing this product.
Jetwash Direct ltd
B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010
6
Mot or M anufactu r er and ty pe Honda GX 340 Honda GX 390
Power HK/RPM 9,5/3600 11,0/3600
Fuel type Petrol Petrol
CCM Cm3 337 389
Fuel tank capacity Liter 6,1 6,1
Moto r RPM, adjusted RPM 3550 3400
Pulley size mm SPZ 55,4/1 SPZ 55,4/1
Motor oil ty pe SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,1 1,1
Type NA5 NA5
Pum p pr essure bar 188 198
Mach ine outl et pr essure bar 167 170
Water Quantity, high pressure l/min 12 13,5
Water Quantity, low pressure l/min 13,5 15
Suct ion capacit y (feeded) meter 3 3
Pum p inlet t em per atu r e °C 35-40 35- 40
Fuel pr essure bar 12 10
Fuel consumption dt = 45 °C kg/h 3,9 3,9
CO
2
con t ent (min.) % 10,5 10,5
Soot rating 0 0
Efficiency % 92 92
Onboard fu el t ank Litre 57 57
Heat er r at in g kW 68 81
Delta T @ workin g pr essure ºC 75 81
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlley Size SPZ 63 / 1 SPZ 60/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 970
Width mm 780 780
Height mm 1000 1000
Weight kg 208 208
Sound power l evel CE, Lwa Db 105 105
High - pressure hose DN8 m 15 15
HP nozzle 0400 0450
NEPTUNE 5-46PE NEPTUNE 5- 54 PE
Miscella
neous
Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchang erGenerator
Jetwash Direct ltd
B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010
7
Mot or M anufacturer and type Honda GX 390 Honda GX 630
Power HK/RPM 11,0/3600 20,8/3600
Fuel type Petrol Petrol
CCM Cm3 389 670
Fuel tank capacity Liter 6,1 20 (External tank)
Moto r RPM, adjusted RPM 3550 3340
Pulley size mm SPZ 55,4/1 SPZ 80/4
Motor oil type SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,1 1,9
Type C3 NP5
Pum p pr essure bar 202 210
Mach ine outl et pr essure bar 192 195
Water Quantity, high pressure l/min 16 20
Water Quantity, low pressure l/min 18 21,5
Suct ion capacit y (feeded) meter 3 5
Pum p inlet t em per atu r e °C 35-40 35-40
Fuel pr essure bar 11 12
Fuel consumption dt = 45°
C
kg/h 4,6 5,75
CO
2
con t ent (min.) % 10,5 10,5
Soot rating 0 0-1
Efficiency % 92 92
Onboard fu el t ank Litre 57 57
Heat er r at in g kW 87 111
Delta T @ workin g pr essure ºC 70 70
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlley Size SPZ 63 /1 SPZ 6 0/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 1130
Width mm 780 910
Height mm 1000 1050
Weight kg 210 260
Sound power level CE,Lwa Db 105 106
High - pressure hose DN8 m 15 15
HP nozzle 0500 0650
NEPTUNE 7-61PE NEPTUNE 5- 85 PE
Miscella
neous
Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchang erGenerator
Jetwash Direct ltd
B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010
8
Mot or M anufac t urer an d t ype Yanm ar Ru gger in i
Power HK/RPM 10/3600 16/3500
Fuel ty pe Diesel Diesel
CCM Cm3 406 Fuel tank capacity Liter 5,5 20 (External tank)
Moto r RPM, adjusted RPM 3530 3500
Pu lley size mm SPZ 80 /3 Motor oil type SAE 15/40 SAE 15/40
Motor oil capacity Liter 1,65 1,8
Type NP5 C3
Pum p pr essure bar 185 185
Mach ine outl et pr essure bar 176 170
Water Quantity, high pressure l/min 13,5 18,7
Water Quantity, low pressure l/min 15 20
Suct ion capacit y (feeded) meter 3 5
Pum p inlet t em per atu r e °C 35-40 35-40
Fuel pr essure bar 10 12
Fuel consumption dt = 45°
C
kg/h 3,9 4,85
CO
2
con t ent (min.) % 10,5 10,5
Soot rating 0 0-1
Efficiency % 92 92
Onboard fu el t ank Litre 57 57
Heat er r at in g kW 81 111
Delta T @ workin g pr essure ºC 81 76
Type t16W-75 t16W-75
Effect W 1000 1000
RPM @ HP and Boiler RPM 2825 2825
PUlley Size SPZ 63 /1 SPZ 6 0/1
Belt dimension Motor/Gen. SPZ 670 SPZ 670
Length mm 970 1130
Width mm 780 910
Height mm 1000 1050
Weight kg 220 315
Sound power l evel CE, Lwa Db 110 112
High - pressure hose DN8 m 15 15
HP nozzle 0450 0650
NEPTUNE 5-51DE NEPTUNE 7-66DE
Miscella
neous
Dimensions
and weight
NEPTUNE PE
MotorPumpHeat exchang erGenerator
Jetwash Direct ltd
B
Technical data
NEPTUNE PE-DE_en_Ver.1.0_October 2010
9
Motor Manufacturer and ty pe Mitsubishi
Power HK/RPM 16/1630
Fuel ty pe Diesel
CCM Cm3 1318
Fuel tank capacity Liter 20 (External tank)
Motor RPM, adjusted RPM 1600
Pu lley size mm Motor oil type SAE 15/40
Motor oil capacity Liter 4,2
Type C3
Pum p pressure bar 200
Mach ine outl et pressure bar 185
Water Quantity, high pressure l/min 19,5
Water Quantity, low pressure l/min 21,5
Suct ion capacit y (feeded) met er 5
Pum p inlet t em per at ure °C 35-40
Fuel pr essure bar 12
Fuel consumption dt = 45°C kg/h 5
CO
2
content (min.) % 10,5
Soot rating 0-1
Efficiency % 92
Onboard fuel tank Litre 57
Heat er r ating kW 111
Delta T @ workin g pr essure º C 76
Type t16W-75
Effect W 1000
RPM @ H P and Boiler RPM 2825
PUlley Size SPZ 63/1
Belt dimension Motor/Gen. SPZ 670
Length mm 1130
Width mm 910
Height mm 1050
Weight kg 510
Sound power l evel CE, Lwa dB 99
High -pr essure hose DN10 m 15
HP n o zzle 0640
NEPTUNE 7-72DE
Miscella
neous
Dimensions
and weight
NEPTUNE P E
MotorPumpHeat exchan ge rGenarator
Jetwash Direct ltd
Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
10
Overview NEPTUNE 5-46PE and 5-54PE
The NEPTUNE 5-46PE is designed with a
NA5 high pressure pump, a NEPTUNE 5
boiler and a HONDA GX340 motor.
5-54PE has a Honda GX390 motor
Fuel pump access through
the square hole on the right
side of the fuel tank.
Honda motor
230V Generator
NA5 pump
Water regulation—pump
By-Pass valve
Temperature sensor—pump
Oil container w/ oil level switch
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
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Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
11
Water outlet
Honda Motor
C3 pump
Water Break tank, OPTIONAL
Water regulator
Anti Scale container, OPTIONAL
Wheels, OPTIONAL
NEPTUNE 7-61PE, front side
NEPTUNE 7-61PE, front side
The NEPTUNE 7-,61PE is designed with
a C3 high pressure pump, a Honda
GX390 motor with 13 HP, control system
same as on the NEPTUNE 3, and a
NEPTUNE 5 boiler
Fuel pump access
through the square
hole in the fuel tank.
Overview NEPTUNE 7-61PE
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
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Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
12
Overview NEPTUNE 7-61PE
NEPTUNE 7-61PE, boiler top
I
N
OUT
Flame sensor Temperature sensor,
boiler exhaust
Fuel nozzle
Electrodes
Temperature
Sensor
Flowswitch
Flowswitch
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Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
13
NEPTUNE 7-61PE, backside
Overview NEPTUNE 7-61PE
Generator, 230V
Top cover Charging relay
Jetwash Direct ltd
Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
14
Overview NEPTUNE 5-85PE
The NEPTUNE 5-85PE is designed with a NP5
high pressure pump, a Honda GX630 motor with
20 HP, control system same as on the NEPTUNE
3, and a NEPTUNE 7 boiler
Honda motor
NP5 pump
Temperature
sensor—pump
Oil glass
w/level
switch
Water
inlet
Unloader
Safety valve.
(This safety valve
is used only on 585PE and 551DE, becasue
the unloader does
not have a safety
valve).
Generator
Battery—12V
Fuel pump access through
the square hole on the right
side of the fuel tank.
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
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Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
15
Overview NEPTUNE 5-51DE
The NEPTUNE 5-51DE is designed with
a NP5 high pressure pump, a Yanmar
motor with 10 HP, control system same
as on the NEPTUNE 3, and a NEPTUNE
5 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Battery 12V Generator
230V
Yanmar
motor
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
Safety valve (only on 5-51DE & 5-85DE)
Unloader & water regulator
NP5 pump
Oil container w/level switch
Thermal dump valve
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
Jetwash Direct ltd
Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
16
Overview NEPTUNE 7-66DE
The NEPTUNE 7-66DE is designed with a
C3 high pressure pump, a Ruggerini motor
with 16 HP, control system same as on the
NEPTUNE 3, and a NEPTUNE 7 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Rugerinni motor
Oil container w/level sensor
Gera box between motor and pump
C3 pump
By-pass valve W/water regulator
Temperature sensor—pump
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
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Construction
C
NEPTUNE PE-DE_en_Ver.1.0_October 2010
17
Overview NEPTUNE 7-72DE
The NEPTUNE 7-72DE is designed
with a C3 high pressure pump, a Mitsubishi motor with 15 HP, control system
same as on the NEPTUNE 3, and a
NEPTUNE 7 boiler.
Fuel pump access
through the square hole
on the right side of the
fuel tank.
Temperature
sensor—pump
By-pass valve
w/ water regulator
C3 pump
Mitsubishi motor
Oil container w/level
sensor
Temperature sensor
exhaust
Temperature sensor water
outlet
Flow switch 1 and 2
A small special
hexagon key for
easy adjustment
of the fuel pressure is placed in the
electric box in all
NEPTUNE PE/
DE machines
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key
moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turning the motor.
In the ”ON” position the battery is continuously charged by the AC generator (9) through the rectifier
(2).
With the key in “ON” position, the hour counter will count, no matter if the motor is running or not.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-46PE, 5-54PE and 7-61PE
Circuit board (A2) is monitoring the thermostat on the high pressure pump (15), the motor
oil switch (8) and the oil level switch in the high pressure pump.
If the thermostat on the pump or the motor oil switch is closing (failure) is respectively input 9 and input 8 connected to ground, which causes the LED to light, and at the same
time output 15 is connected to ground.
If the oil level switch closes (failure) input 5 is connected to ground, output 15 is also connected to ground, which pulls the relay (6) and the motor stops. Also the LED for low oil
level will light up.
On this model it is important that the jumper on A2 (2A) is NOT mounted.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-51DE
Start the motor by shortly turning the key (5) into the start position. When you let go the key, the key
moves back to the ”ON” position.
When the key is turned to the start position, the start relay (13) is pulled, and the start motor is turning the motor.
Circuit board (A2) is monitoring the thermostat (E) on the high pressure pump, the motor oil switch
(D) and the oil level switch in the high pressure pump.
If the thermostat (E) on the pump is closing (failure) is input 8 connected to ground, which causes
the LED to light, and at the same time output 15 is connected to
ground.?????????????????????
If the charging generator (I) is not charging, wire (Y) in the regulator (O) is getting 12V and also the
input 7 on A2 is then getting 12V, which makes the charging light lighten.
On this model it is important that the jumper on A2 (2A) is NOT mounted, for the charging system to
work properly.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 7-66DE
When the key (S1) is turned to start, the start relay is pulled and the motor starts. Then let go the
key, and it moves back to the ”ON” position.
The motor oil pressure switch (B10) is a normally closed switch. In closed position (motor not running) the switch is connected to ground. When the motor starts and the RPM increases the motor oil
pressure increases the switch opens and there is no connection to ground anymore. When no connection to ground there is no ground on output 15, which means the motor runs.
If output 15 is connected to ground 5 sec. after the key is turned back to “ON” position, contactor K3
is pulled, and the fuel pump is disconnected for 9 sec. (done by TIM 2—Timer for motor stop) —
motor stops.
If there is a failure on sensor B5, B 10 or B11, and by that output 15 is connected to ground, the fuel
pump will be disconnected in 9 sec., and the motor will stop.
If the 12V charging is not functioning input 6 on A2 will be connected to ground.
IMPORTANT: JUMPER ON A2 MUST BE MOUNTED
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 7-72DE
When the key (S1) is turned to the ”ON” position, the glow timer (Tim1), and the glow relay (K3) is
activated, and the glow plugs (R1) are heating, and also the glow lamp on A2 is lightening. After a
short while the timer runs out and the glow relay opens.
Now the key can be turned to the start position, and the starter coil (Y2—red wire), together with the
holding coil (Y2—white wire) is pulled and runs the starter motor, and the motor will start.
Now release the key, so it goes back to the “ON” position, the starter coil (Y2—red wire) is no longer
pulled, but the holding coil (Y2—white wire) is kept hold through the contactor (K3).
If there is a failure on B5 (oil level switch pump oil), B10 (Motor oil switch), B11 (thermo switch motor) or B12 (thermo switch high pressure pump), output 15 on A2 is connected to ground, contactor
K3 opens and the holding coil Y2 opens and the motor stops.
It is important that the jumper is mounted on the circuit board (A2). When jumper mounted there is
12VDC on output 7 on A2. Output 7 is connected to connection “R” on the generator. The generator
(G1) can only give output, if there is 12VDC present on connection “R”. If the generator is “worn/
defect” the DC voltage on connection “L” drops down to 0 VDC, and input 6 on A2 in then connected
to ground, and the charging LED will light up.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of NEPTUNE 5-85PE
If there is a failure on B5 (oil level switch pump oil), B10 (motor oil switch) or B12 (thermo switch
high pressure pump) is output 15 on A2 connected to ground. At the same time input “F” on the
Honda motor is connected to ground, and the Honda motor will stop.
IMPORTANT: JUMPER ON A2 MUST BE MOUNTED
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of Circuit Board, A1
The circuit board used in all NEPTNE PE/DE machines is the same as used in NEPTUNE 3.
The only difference is the following bridges which are mounted on the circuit board in the NEPTUNE
PE/DE machines.
X4,5 to X5,6—oil level switch high pressure pump. Oil level switch is moved to circuit board A2
X4,1 to X4,2—Anti-stone
X3,5 to X3,6—Thermal switch in high pressure pump motor.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of Circuit Board, A1
Control Circuit Board (A1) is functioning the same way in all the NEPTUNE PE/DE models. The
power supply to A1 is supplied by the 230V generator G2, which is driven by the motor. This means
that the motor must be running—and running at full RPM—before the A1 is working. In cold water
mode the S1 main switch can be in position ON or OFF. If S1 is turned to the temperature area (red)
the hot water mode is activated.
When S1 is turned to ON power is supplied through the fuse F1 to the microprocessor. The microprocessor is starting up, and the 5 status LED’s is lightening up for 1 sec. If there is a failure during
start up, the control circuit board goes into failure mode.
If the S1 main switch is turned to “hot water mode”, and the spay gun is open, and desired temperature set at S1, B1 temperature sensor is measuring lower temperature that the set point at S1, and
B9 fuel level sensor is measuring fuel in the tank, and B2 flow switch, and B4 flow switch is registering water flow, the burner motor M2 is started, and the ignition transformer T2 is started over the
burner relay K3. A high voltage spark is generated between the electrodes in the burner.
The burner motor M2 is driving the burner fan, which is blowing pre-heated air into the boiler. The
self-sucking fuel pump is pumping fuel pressure up to the fuel solenoid valve Y1. When the burner
motor/fan has been running in 1 sec., the fuel solenoid valve Y1 opens, and the fuel is pumped under pressure to the fuel nozzle. The atomized fuel is leaving the fuel nozzle and is ignited.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of Circuit Board, A1—Continued
The flame sensor B7 is controlling if the fuel is ignited, and if it is (the flame sensor can see the
flame) it “allows” the burner to burn.
If the flame sensor don’t see the flame after 4 sec. (when S1 is in hot water mode), the fuel solenoid
valve will close, and the burner will be stopped.
If the display is flashing in the LED’s, it can be due to too low RPM on the motor.
If the LED’s are flashing, it means that the voltage is too low to maintain the circuit board.
The flashing LED’s means that the display is “re-starting” all the time.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Functional desription of Circuit Board, A1—Continued
Control Circuit Board:
Pos. 1: The heating and ON/OFF switch (S1)
Pos. 2: Heating Relay (K2)
Pos. 3: LED’s
Pos. 4: Fuse—Self-resetting ”Pico fuse”
Pos. 5: Fuse
Pos. 6: Fuse
Control Circuit Board A1
On the above picture is the correct setting of the
circuit board.
Arrow 1
Setting is WITHOUT JUMPER = By-pass time
active
Arrow 2:
Setting is JUMPER MOUNTED ON PIN 2 AND 3
= Flame Sensor active.
Circuit board (A2) has LED’s for
the motor, e.g. water temperature,
motor oil level etc.
Circuit Board A2 (A1)
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
NEPTUNE PE/DE—NP5 PUMP
The 3piston radial pump NP5 is used in the NEPTUNE 5-85PE and 5-51DE
OUT
IN
Suction valve
Pressure valve
OIL
Cam shaft
Shaft
The three pistons are driven by the motor via a belt drive. The cam shaft transforms the
rotation power into the pistons reciprocating movements.
The movement and the diameter of the pistons decide the water volume which can be
sucked into the suction valves and pressed out through the pressure valves.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
NEPTUNE PE/DE—NA5 PUMP
The 3piston NA5 pump is used in the NEPTUNE 5-46PE and 5-54PE
The NA5 pump is connected to the Honda motor with a direct drive.
By-pass valve function is described later in this service manual.
Honda motor and D-bearing cover
Pistons, cylinder block,cylinder head
and sealings
Water inlet
By-pass valve with water regulator
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
NEPTUNE PE/DE—C3 PUMP
The 4 piston C3 pump is used in the NEPTUNE 7-61PE, 7-66DE and 7-72DE
The wobble disc is mounted directly on the motor shaft.
Water is sucked through the suction valves and out through the pressure valves and the pis-
ton in the by-pass valve. The piston has two small holes where the water is running through
in order to create a pressure drop, which make sure the valve cone is closed during operation.
When water flow is interrupted, the pressure rises until the safety valve opens. Because of
the achieved pressure drop, the valve cone is pressed to open so the water re-circulates at a
pressure < 10 bar.
Water quantity is regulated by a handle in the end of the by-pass valve. When turning the
handle clockwise, the by-pass valve cone will be forced open, so some of the water is recirculating in the pump.
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NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
By-Pass valve function NEPTUNE 5-46PE and 5-54PE
A
B
I
C
D
J
E
F
G
H
K
Machine is started and the gun ”J” with correct lance/nozzle is open -
Machine runs in working pressure ”K”:
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.
Working pressure
A
B
I
C
D
J
E
F
G
H
K
Machine is started and the gun is closed - By-pass pressure:
When the gun ”J” closes, the pressure inside the by-pass housing equalizes and the by-pass
piston ”B” is pressed down by the tension of it’s spring. The seat ”E” in the top of by-pass piston
opens. The water runs from the pump outlet ”A” into the by-pass housing ”C”. Due to the closed
gun ”J” and the opening in the by-pass seat ”E”, the water runs back into the suction side of the
pump through the valve ”D”.
By-pass pressure
Jetwash Direct ltd
D
32
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
A
B
C
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 ”B”.
When the screw is tightened the cut off pressure will rice and by loosening it the pressure will
fall.
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.
A
B
I
C
D
E
F
G
H
K
When the water regulation ”G” is turned counter clock wise, the seat ”H” opens and the
water runs both to the outlet of the by-pass housing and in by-pass to the suction side of
the pump.
The pressure ”K” will fall depending of the size of the opening in seat ”H”.
Water reduction
By-pass pressure
By-Pass valve function NEPTUNE 5-46PE and 5-54PE
Jetwash Direct ltd
D
33
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
By-Pass valve function NEPTUNE 7-61PE, 7-66DE, 7-72DE
Operation:
The water from the pump is lead into
the chamber ”A” in the by-pass valve.
From here the water passes through
the holes “B” in the by-pass valve piston “C” and out to the high pressure
nozzle. When water is pressed
through holes in the piston “C”, there is
a pressure drop over the piston (this
means the pressure is higher on one
side of the piston). This will keep the
valve cone “D” closed against its seat
“E”, because the piston “C” is fixed to
the valve cone.
By-Pass:
When the water consumption stops
(spray handle is released/closed), the
pressure drop over piston “C” disappears, the pressure in the by-pass
valve increases briefly until the safety
valve “F” opens. The safety valve just
opens briefly, and closes again. The
safety valve opens when the pump
pressure overcomes the tension of the
spring in the safety valve. (The safety
valve is adjusted to open 25-30 bar
above normal working pressure). Now
the valve cone “D” lift from its seat “E”,
and water runs in by-pass.
Jetwash Direct ltd
D
34
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Unloader valve function NEPTUNE 5-85Pe AND 5-51DE
Unloader mounted on pump
Unloader disassembled
Unloader function:
On the assumption that the black handle
(adjustment handle) on the unloader is turned all
the way to max. pressure (clockwise).
When the pump is running the unloader piston (2)
is pressed down it its seat (1), and all the water
volume is going through the gun and out to the
high pressure nozzle.
When the gun is released (no water flow out), the
pressure in the unloader will rise, and the increased pressure will overcome the adjusted tension of the unloader spring (6), and the unloader
piston (2) will be lifted up from its seat.
Water will now return through the seat (1) to the
suction side of the pump (by-pass) mode.
Jetwash Direct ltd
D
35
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Flow switch function NEPTUNE PE
Flow switch
Plug with Shaft
Water supply connected to the machine.
Water from the pump is pressed through the high pressure hose to the first flow switch.
When water is entering the first flow switch, the piston with magnet is pressed to the top of the flow
switch housing, and the reed switch is making contact and closing the circuit.
(Reed switch is a NO contact)
Water is now pressed through the second flow switch, the piston with magnet is pressed to the far
end of the housing, and the reed switch is making contact and closing the circuit.
When the spray handle is released and the water flow stops, the flow switch pistons will move away
from the reed switches, and the will brake off the circuit and the burner will stop.
When the water flow stops, the piston in the first flow switch will fall down and be stopped by the
plug with the shaft. The plug with shaft is installed to reduce the movement of the piston.
The signals from the two flow switches must come simultaneously. (MAX. difference between the
two signals are 4 seconds)
The signals from the flow switches are controlling the fuel pump solenoid valve. This to make sure
that the burner is not starting if there is no flow of water through the heating coil.
Jetwash Direct ltd
D
36
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Heat exchanger NEPTUNE PE
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 baffle plate
(2). This preheats the air before it
mixes with the fuel spray from the
fuel nozzle (3).
Cold water is fed to the inner circuit
in which the temperature is highest.
This reduces in as much as 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 nozzle stock (8) with the fuel
nozzle (3). If no combustion is
needed, the fuel goes back to the
tank on the return line (9).
The ignition transformer (10) activated in "Hot water" mode generates ignition sparks across the electrodes (11) to ignite the fuel spray.
This process is monitored by the
flame sensor (12).
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 flue
(13).
Heat exchanger (schematic)
Fig. D.19:
1) Burner fan
2) Baffle plate
3) Fuel nozzle
4) Heating coil
5) Fuel pump
6) Fuel filter
7) Solenoid valve
8) Nozzle stock
9) Fuel return line
10) Ignition transformer
11) Ignition electrodes
12) Flame probe
13) Flue
14) Flame sheath
15) Flame funnel
16) Insulation
17) Water inlet
18) Water outlet
Jetwash Direct ltd
D
37
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Function
Safety Thermal Temperature Sensor in boiler exhaust
Located in the heat exchanger outlet (flue) is a temperature-dependent resistor (Pt 100) functioning as a temperature sensor.
If the temperature in the heat exchanger outlet (actual
temperature) exceeds the temperature set-point, the solenoid valve Y1 closes to interrupt the fuel feed. The
temperature sensor is only activated in "Hot water"
mode.
The safety thermal release mounted on the heat exchanger water inlet, is an absolute safety
element on the heat exchanger.
If a fault is present, e.g. all control and safety devices fails, and hot water flows at high pressure from the heat exchanger back through the safety valve into the high pressure pump, the
thermal release responds and shuts down the entire machine through the control circuit. Before restarting, the machine must cool down, the fault causing the heated water to flow in the
wrong direction must be corrected, and a new thermal release fitted.
The flame sensor is a light-sensitive phototransistor.
The flame sensor checks for the presence of a flame.
Jetwash Direct ltd
E
Troubleshooting
NEPTUNE PE-DE_en_Ver.1.0_October 2010
38
Fault Cause Remedy
Green LED illuminates.
⇒ Machine ready to opeate.
All LEDs flash once before the motor is turned
on.
Yellow LED illuminates.
⇒ Fuel level is low.
• Refill fuel. "Cold water"
mode is possible.
Yellow LED flashes.
⇒ Alto Anti Stone level is
low.
• Refill Alto Anti Stone.
"Hot water" and "Cold
water" mode is possible.
Red LED illuminates.
⇒ Pump oil level is low.
• Refill pump oil (Chapter
F.1.3). The burner and
motor are cut out. The
green LED extinguis-
hes.
Red LED flashes.
⇒ Service interval: service
due in 20 hours.
• Service the machine.
"Hot water" and "Cold
water" mode is possible.
Red LED illuminates.
⇒ Service interval elapsed.
• Service the machine.
"Hot water" and "Cold
water" mode is possible.
Jetwash Direct ltd
E
Troubleshooting
NEPTUNE PE-DE_en_Ver.1.0_October 2010
39
Fault Cause Remedy
Green LED flashes.
⇒ Flow sensor fault.
⇒ Water tap closed or wa-
ter flow inadequate.
⇒ Detergent tank empty.
⇒ Pressure rate control or
Vario Press set for too
small amount of water.
⇒ Machine scaled up.
• See Chapter F.3.3,
F.3.5 and G.3.4."Cold
water" mode is possible.
• Requirements in Chap-
ter B.
• Refill detergent or set
the SDR valve to "0".
• Set the pressure rate
control or Vario Press
for a higher water flow.
• Descale the machine.
Green LED and
red LED flash simultaneously.
⇒ Leakage or impermissi-
ble operating status
through brief operation.
⇒ Spray pistol leaking.
⇒ HP hose, HP coupling or
pipe leaking.
⇒ Detergent tank empty.
⇒ Filter clogged in water
intake.
⇒ HP pump sucking in air.
• The machine cuts out
after being briefly operated three times. Reset:
set the main switch to
"Off". Operate the pistol
for > 3 s.
• Check the spray pistol.
• Tighten the screws, re-
place the HP hose or
pipe.
• Refill detergent.
• Clean the filter
• Correct leaking points.
Jetwash Direct ltd
E
Troubleshooting
NEPTUNE PE-DE_en_Ver.1.0_October 2010
40
Fault Cause Remedy
Green LED and
red LED flash alternately
⇒ Motor/machine over-
heated (MT has triggered).
⇒ Thermal release B3 has
tripped.
⇒
⇒ 24 Vac fine-wire fuse F2
has blown.
• Set the main switch to
"Off". Allow the machine
to cool.
• Work without an exten-
sion cable or use an extension cable with a larger cross-section.
• Possibly a phase failure:
have the electrical connection checked.
• Correct the cause of the
fault (Chapter D.2.3.5)
and replace the thermal
release (Chapter F.7.4).
• Correct the cause of the
fault and replace the
fine-wire fuse (Chapter
F.8.1).
Green LED
flashes slowly &
red LED flashes
fast
⇒ Fault in fuel or ignition
system, burner fault.
⇒ Flame probe (option)
sooted up.
• See Chapter F.2.6 and
F.7. "Cold water" mode
is possible.
• If this option is fitted, re-
move it and clean it.
Jetwash Direct ltd
E
Troubleshooting
NEPTUNE PE-DE_en_Ver.1.0_October 2010
41
Fault Cause Remedy
Green LED does
not illuminate.
⇒ No power to microproc-
essor.
• Make sure the machine
is plugged in.
• Operate main switch S1.
• Check the primary and
secondary voltage (8
Vac) on transformer T1.
• Pico fuse F1 has blown
(self-resetting). Wait until F1 is reset or, if the
fault persists, replace
electronic controller A1
(Chapter F.8.1).
Pressure too low.
⇒ HP nozzle worn.
⇒ Pressure rate control or
Vario Press set for too
low a pressure.
⇒ Flexo Power nozzle
open.
• Replace the HP nozzle.
• Turn the pressure rate
control on the unloader
valve in the direction
"+", or set the Vario
Press rotary knob
(accessory) on the pistol
for a larger amount of
water.
• Close the Flexo Power
nozzle.
Machine runs jerkily.
⇒ HP pump taking air in
from empty detergent
tank
• Close the detergent dos-
ing valve. Take the
spray pipe off the spray
pistol. Operate the spray
pistol and let the ma-
chine run until the air is
expelled from the sys-
tem and the pump works
smoothly.
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
42
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
43
Valves
• Dismount the valve housing from the
cylinder block by the three M12 bolts.
• Be aware of the o-rings and valve parts.
• Be carefull not to damage the surface
inside when dismounting the thrust collar.
• Inspect the thrust collar for damages
before mounting.
Fig.F.14: Thrust collar Fig.F.13: Valve housing
Fig.F.15: Valve housing Fig.F.16: Valve housing
• Carefully tip out the sleeves with an
adequate screwdriver and replace them. Be
careful not to scratch the surface.
• 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.
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
44
• Overview of the placement of suction valve
parts.
Fig.F.19: Pressure valves Fig.F.20: Pressure valve seat
• Overview of the placement of pressure
valve parts
• Take out the pressure valve seats with
an adequate puller or use an 8mm
threaded pin.
• Replace with new parts if necessary.
Picture of piston guides
• The pressure valves can easily be taken
out of the cylinder head.
• Replace with new parts if necessary.
Pic. F.17: Suction valves Pic. F.18: Pressure valves
Valves
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
45
Fig.F.24: Pistons
Fig.F.23: Valve Kit 3~ - Exploded View
Fig.F.21: Cylinder block
Cylinder Block
Fig.F.22: Oil Sleeves
• Overview of the placement of the parts in
the cylinder block.
• Take out the oil sleeves using an
adequate screwdriver.
• Be careful not to damage the surface of
the cylinder block.
Oil seal and piston
NEW !
• To make replacement easier moisten the
sleeves with soapy water.
• Mount the sleeves using a 19mm box
spanner and a fiber hammer.
• Place sleeves, pistons and springs as
shown.
• Mount the cylinder block to the D-bearing
cover by the two 6mm mounting screws.
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
46
Wobble disc
• 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.25: Pump head Fig.F.26: D-bearing cover and wobble disc
Fig.F.28: Wobble disc removal Fig.F.27: Wobble disc
• Demount the wobble disc screwing a 1
6mm bolt into the threads. Tighten the
bolt against the motorshaft and pull the
wobble disc out.
• 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.
• Overview of the parts inside the D-
bearing cover.
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
47
D-bearing cover
Fig.F.30: Oil sleeve Fig.F.29: D-bearing cover
• The D-bearing cover is mounted to the
Motor by four 6mm bolts.
• When the bearing is damaged, always
replace the complete D-bearing cover.
• The oil sleeve in the D-bearing cover can
be demounted carefully using a
screwdriver.
• Mount the oil sleeve by using an
adequate box spanner and a fiber
hammer.
NA5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
48
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
49
Mandrel no.: 1216506
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
50
Mounting of textile sleeves by means of tool no. 1220090. It is an
advantage if the sleeves havebeen in a water bath for 3-4 hours before
mounting them. Do not forget to blow air through the ducts.
Ke
nn
e
y
Duct
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
51
Always replace
secondary sleeves when
replacing pressure
sleeves. Check that there
is a free passage from
the drain holes.
Drain off the oil. Loosen the 8 bolts gradually (because of the spring load). Special
box head no.1206762 may be used.
Mount new O-rings on studs with tool no. 1206812.
Washer
O-ring
Thrust collar
Torque: 37 Nm
Oil sleeve
Secondary sleeve
Spacer ring (Crovn)
Spacer ring
O-ring Back-up ring
Secondary sleeve
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
52
Carefully tip out the oil sleeves
with an adequate screwdriver and
discard them. Be careful not to
scratch the surface.
Before mounting the new sleeves,
it will be a good idea to moisten
the sleeves with soapy water.
Mount new oil sleeves with punch
no.1220429. Carefully knock or
press them home.
Oil sleeve LP HP
Check the piston for wear
in the pressure area and
the area fPressure area
(rides on wobble disc)
or oil sleeves. Check the
ceramic for cracks. Remove any coating.
Pressure area,
touches
the bearing disk
Stainless steel
Ceramic
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
53
Dismount locking ring on the rotor shaft.
The wobble disc is easily dismounted
with puller no. 1205715 and special legs
no. 1206150/1206168. Do not forget to
remove the key before dismounting the
D-bearing cover.
Check bearing surfaces for wear. If in
doubt, replace kit complete after approx.
2000 hours.
When mounting the D-bearing cover complete,protect the U sleeve with tool no.
1206598 which is placed on the shaft, before placing the cover.
Tool : 1206598
When mounting the wobble disc, lubricate
the bearings with oil. The big roller bearings
are identical. Do not forget to mount the
circlip on the rotor shaft. Refill with 1 l oil
type Castrol Alphasynt ISO 150.
Check the bearing surfaces for wear. As
long as the wear is even and shiny without
pittings or grooves, the wobble disc can be
Pittings
C3 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
54
V al v e cover & seals.
Pistons & oil seals.
Pum p h .
ousing
Motor
NP5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
55
Dismount the brass plug on the
cylinder head with a 21mm fixed spanner
and remove the valves.
Do not scratch the inside of the valve
chamber during removal!
When you replace the valves
give the o-rings an inspection
for damage before mounting.
NP5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
56
Be careful when you dismount thrust collar because you can easily damage the
surface inside. Give the thrust collar an
inspection before mounting.
When mounting the sleeves
and the spacer, remember
lubricating.
When dismounting the suction sleeves,
use a screwdriver to tip out the sleeves.
Do not reuse the sleeves.
Clean the thrust collar and lubricate before
mounting the sleeves as shown in the
ilustration.
Inspect the the thrust collar for marks,
lubricate and mount it with your fingers.
5
3 1
7
8
2
4
6
When you mount the cylinder head
tighten the bolts in the shown
sequence Use a 6mm hexagon wrench.
NP5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
57
Piston & Oil Seal
To inspect the plunger for cracks. Spray the inside of the plunger with fast evaporating cleaner
such as a brake cleansing agent. The brake cleansing agent will take a second longer to evaporate from the crack, thus making the crack visible.
T
orque
106 Inch pounds
8,8 ft.lbs
13NM
Backup-ring
O-ring
Copper washer
Bras s slin ger plate
Oil seal
Carefully inspect and replace as needed, Orings and backup rings on the plunger rod
prior to reinstalling the plungers.
Also clean the brass slinger plates before reinstalling the plungers.
Do not re-use the copper washers!
Use one drop of medium strength thread locker on each plunger rod when reinstalling plunger
nut and torque to specifications.
Oil seals must be changed if there any signs of leaks or if they are removed.
The recommended way to remove the oil seals which are pressed into the pump body is to
sew the seal with an awl and pry down.
When installing new seals, a light coating of lubricant on the seals may ease the installation.
Make sure it is pressed in using equal pressure around the entire circumference.
NP5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
58
NP5 Unloader valve
NP5 Unloader valve parts
NP5 Unloader valve
NP5 Pump
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
59
Insolation
Mounting plate
Fixation spacer
Inner jacket
Outer jacket
Burner tube
Top plate
Water outlet
Exhaust
Fuel nozzle Electrodes Flame sensor
Air distributor
Water inlet
Flame tube top part
Flame tube
Air inlet
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.
Boiler
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
60
3
6
7
4
2
4
5
9
10
8
X
Y
9
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.
Check the flame tube marked with X
and Y. It is important
that they are solid
and complete.
Y is a part of the coil
8 and cannot be separated.
Clean the coil.
9
Clean up deposits and
change the isolation if
needed.
Boiler
Burner Unit.
1
2
3
4
5
6
7
1. Fuel solenoid
2. Fuel pump
3. Burner motor
4. Burner housing
5. Fuel filter
6. Fan
7. Fan cover
Burner fan and fuel pump.
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
61
Electrodes
6mm
4 mm
5 mm
Spring washer
The electrode is adjusted from factory.
If the distance between the legs becomes greater than 4 mm, the electrode
must be changed.
The electrode 18 is self adjusting the
position on the nozzle by a spring
washer 19 under the fixing screw 20.
7
6
13
21
22
4
5
9
10
12
14
11
17
19
18
20
The flame sensor 9 must be fixed
with 5 in the right position.
Clean the flame sensor
Burner Electrodes
Jetwash Direct ltd
F
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Service / Repair
62
As
required
Water filters
Oil filter
Checking the pump oil qua lity
Changing the pump oil
Emptying the fuel oil tank
NP 5 pump only:
After the first 50
operating hours
C3 and Na5
pump every six
months or
500 operating
hours
Weekly
Maintenance plan
Maintenance
Jetwash Direct ltd
G
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjustment / Test
63
NA5 pump
20 Nm
20 Nm
10 Nm
40 Nm
65 Nm
25 Nm
By hand
Torque specifications
Fig.G.01: Wobble disc
Fig.G.02: Cylinder block
Fig.G.03: Cylinder head Fig.G.04: Venting valve
Fig.G.05: By-pass housing
40 Nm
Fig.G.08: Water regulation Fig.G.07: Outlet fittings
Fig.G.06: Venting valve
IMPORTANT:
When torque settings are made, all parts — Pump, screws
etc. must have a temperature at 20°C.
Jetwash Direct ltd
G
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjustment / Test
64
Dismount the test plug in the by-pass housing
and mount a pressure gauge instead.
Adjustment of by-pass system.
Fig.G.09: Pressure gauge Fig.G.10: Test tap
Fig.G.11: Safety valve Fig.G.12: Pressure bolt
Connect a test tap (A), hose and pressure
gun to the outlet of the machine.
Close the safety valve completely. Adjust the test tap (A) and the pressure bolt
(B) so it couples 20-30 bars higher than
working pressure, when the pressure gun is
closed— CUT OFF PRESSURE. After the
cut off pressure is reached the machine
runs in by-pass untill the pressure gun is
opened.
The working pressure is stated in the technical data sheets chapter B.
A
B
NA5 pump
Jetwash Direct ltd
G
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjustment / Test
65
Adjustment of by-pass system.
Pressure bolt
When adjustment is done, lock the bolt with
the counter nut.
Then let the machine run just below the cut
off pressure (working + adjustment) and adjust the safety valve out until it couples out
(go into bypass). Then you adjust the adjusting “screw” a ½ turn back and lock it
with the counter nut.
Finalize the adjustment with locking glue/
paint on both the bolt and the safety valve.
Safety valve
NA5 pump
Jetwash Direct ltd
G
NEPTUNE PE-DE_en_Ver.1.0_October 2010
Adjustment / Test
66
Adjustment of by-pass system.
C3 pump
Pos. 1 Safety valve adjustment
Pos. 2 Set screw for min. Water adjustment
Pos. 3 Min. Water adjustment screw
Minimum water volume (and pressure) adjustment:
First mount test manometer with correct high pressure test nozzle.
Turn the black handle on the water regulator all the way clockwise. (Min. Water volume)
Start the motor and run at full RPM.
Test manometer must show approx. 30 bar. If this is not the case, loosen set screw (pos. 2),
and then turn the min. Water adjustment screw (pos. 3) untill you reach approx. 30 bar.
Safety valve adjustment:
First mount test manometer without test nozzle—just open outlet.
Turn the black handle on the water regulator all the way counterclockwise. (Max.. Water volume)
Start the motor and run at full RPM.
Slowly
close the valve on the test manometer, and read the pressure when the safety valve
opens. (That will be the pressure just before the pressure drops)
The opening pressure for the safety valve must be 25-30 bar above normal working pressure.
To adjust the opening pressure, loosen the lock nut (pos. 1) with a 22 mm Open/ring spanner.
Then adjust the safety valve by turning the adjustment screw with a 6 mm. Allen Key, When
turning clockwise—opening pressure increases, and counterclockwise it decreases.
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Adjustment of Unloader system.
NP5 pump
Turn the black handle clockwise
as far as it can.
This is max. pressure adjustment.
Using a screwdriver or similar tool,
to remove the cap on top of the
unloader.
13 mm Box spanner
Loosen the lock nut on the pressure adjustment bolt. Use a 13
mm. box spanner.
Adjust the pressure with a 7 mm. Hexagon
Allen Key the following way.
Start machine with correct HP nozzle.
Loosen unloader until pressure drops, then
turn ½ turn clockwise, to obtain full pressure
again.
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Adjustment of Unloader system.
NP5 pump
When the correct pressure is adjusted, tighten the lock nut with a
13 mm. Box Spanner.
Mount the cap on top of the
unloader. Now the correct adjustment of the unloader is done. By
turning the handle counterclockwise, you can reduce the pump
water volume and pressure.
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Note: Higher CO2 concentrations at different barometric pressure, altitude or temperature and poor
quality of the used fuel can lead to faster soot deposition on the heating coil of the heat exchanger.
Preparation
1. Set the fuel pressure.
2. Let the machine run in "Hot water" mode for at least two minutes so that it reaches operating
temperature and meaningful results can be measured.
Note: Machines that are primarily used for a brief period should run continuously for about half an
hour in "Hot water" mode before an exhaust measurement.
Measurement
3. Determine the soot rating with a soot pump and soot rating reference scale. The figure should not
exceed "1". Otherwise, open the air flap a little and repeat the measurement. Repeat the procedure
until the specified value is obtained.
.
4. Then the CO2 content in the exhaust, the intake and exhaust temperature are determined. This
can be done with conventional meters or with an electronic meter like the TESTO 325, which
measures and displays all relevant data.
If the measured value is too low, close the air flap a little and check the soot rating and Co2 content
again.
Repeat all settings until all specified values are obtained.
5. Finally seal the set screw (arrow A) of the air flap with varnish.
Burner settings.
• Mount pressure gauge on the fuel pump.
• Adjust the fuel pressure according to the
values in Technical data chapter A.
Air flap.
•
The air flap on the side of the burner fan is
adjusted by a self-locking spindle on a set
screw. Turning clockwise increases the air
intake, turning counterclockwise reduces it.
Fuel pressure setting.
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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 measurement. Repeat the procedure until the specified
value is obtained.
Fig.G.17: Soot raiting
The CO2 content in the exhaust, the intake
and exhaust temperature are determined.
This can be done with conventional meters
or, as in Fig. G.08, with an electronic meter
like the TESTO 325 (4), which measures
and displays all relevant data.
If the measured value is too low, close the
air flap (Fig.G.06) a little and check the soot
rating and Co2 content again.
Fig.G.18: Burner measurements.
Burner settings.
1. BR1
2. BR2
3. X5—For Datalogger and Service Interval
4. ”Fuel” LED
5. ”Antistone” LED
6. ”Service” LED
7. ”Pump Oil” LED
8. ”Operation” LED
Service time setting:
Switch off machine with S1. install a jumper on X5 between pin 3 and 5. Switch on machine
(cold water mode). With the temperature setting knob it is now possible to set a new service
interval. The reading is done by the LED’s (4,5,6,7 and 8), where (4) is 100 hours, 4+5 is 200
hours and so on, up to 500 hours when all LED’s are on. If setting is not changed for 3 sec.,
the setting is saved. This can be seen when the chosen LED’s are flashing. Machine must now
be switched off, and the jumper removed from X5. Default service setting from factory is 200
hours.
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Boiler
4. Flame sensor.
5. Fuel nozzle.
6. Air distributer.
Fig.F.49. Boiler top
2.
1.
3.
4.
5.
6.
1. Ignition Transformer.
2. Ignition cords.
3. Ignition electrodes
5mm
4mm
Fuel nozzle.
5mm
Fuel nozzle.
Heating system - Overview.
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NEPTUNE PE 1 Cylinder Honda, Page 1 of 3
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Notes
Jetwash Direct ltd
JETWASH DIRECT LTD
www.jetwashdirect.co.uk
sales@jetwashdirect.co.uk
Jetwash Direct ltd
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