Nilfisk-ALTO NEPTUNE 1 Service Manual
  1. Manuals
  2. Brands
  3. Nilfisk-ALTO Manuals
  4. Scrubber
  5. NEPTUNE NEPTUNE 1
  6. Service manual

Nilfisk-ALTO NEPTUNE 1 Service Manual

Hide thumbs Also See for NEPTUNE 1:
Table of Contents

Advertisement

Quick Links

NEPTUNE 1
NEPTUNE 2
NEPTUNE 2 SPECIAL
Service Manual
Ver.2.1

Advertisement

Table of Contents
loading

Related Manuals for Nilfisk-ALTO NEPTUNE 1

Summary of Contents for Nilfisk-ALTO NEPTUNE 1

  • Page 1 NEPTUNE 1 NEPTUNE 2 NEPTUNE 2 SPECIAL Service Manual Ver.2.1...
  • Page 2 Preface This service manual contains detailed description of the main repair work on the hot HPW NEPTUNE 1, NEPTUNE 2 & NEPTUNE 2 Special. Repair work requires a suitable testing workplace with the necessary water and power supply. If operating errors are evident, refer the customer to the operating instructions.
  • Page 3 Safety instructions Technical data 5-52 Construction 53-54 Function 55-68 Troubleshooting 69-70 Service / Repair 71-98 Adjustment / Test 99-103 H. Wiring diagrams 104-107...

  • Page 4: Safety Instructions

    Use a conductive floor covering or a conductive table cover.  Never touch the printed circuit board or electronic components  ( always hold on to plastic ). Transport electronic components in conductive packaging  ( e.g. ESD bag ). NEPTUNE 1&2_EN_Ver.2.1_45/2014...

  • Page 5: Technical Data

    Technical data Parent item no: Description: 107145000 NEPTUNE 1-22 EU 230/50/16A Service data Unit Value NEPTUNE 1-22 Model 107145000 Item no. TECHNICAL DATA PUMP: Pump pressure water Pressure pump outlet @ Qiec Pressure gun outlet @ Qiec Retaining pressure* Flow. Qiec...
  • Page 6 Technical data Parent item no: Description: 107145000 NEPTUNE 1-22 EU 230/50/16A Service data Unit Value BOILER: Boiler power input Exhaust temp °C 20 ±10 Ambient temp. @ Burner values °C Fuel tank (Boiler) Boiler fuel consump.@∆T=45C Burner efficiency 0,75 60H...
  • Page 7 Technical data Parent item no: Description: 107145001 NEPTUNE 1-22 GB 230/50/13A Service data Unit Value NEPTUNE 1-22 Model 107145001 Item no. TECHNICAL DATA PUMP: Pump pressure water Pressure pump outlet @ Qiec Pressure gun outlet @ Qiec Retaining pressure* Flow. Qiec...
  • Page 8 Technical data Parent item no: Description: 107145001 NEPTUNE 1-22 GB 230/50/13A Service data Unit Value BOILER: Boiler power input Exhaust temp °C 20 ±10 Ambient temp. @ Burner values °C Fuel tank (Boiler) Boiler fuel consump.@∆T=45C Burner efficiency 0,75 60H...
  • Page 9 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 240V/1ph/50Hz/9,6A/2,2kW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 10 HP-Hose DN6X10M for swivel quick 3/8" Hose Guaranteed sound power Impactfactor calculated 13,3 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 11 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 230V/1ph/50HZ/14.5A/3.4KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 12 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 13 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 230V/1ph/50HZ/14.5A/3.4KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 14 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1071 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 15 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 230V/1ph/50HZ/12.4A/2.9KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...

  • Page 16: Neptune 2-25 Gb 230/1/50/13

    HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 17 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 230V71ph/50Hz/12.5A/2.9KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 18 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1071 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 19 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 220V/1ph/60Hz/14.3A/3.2KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421565 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 20 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 21 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 240V/1ph/50Hz/14,5A/3,4kW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 22 HP-Hose DN6X10M for swivel quick 3/8" Hose Guaranteed sound power Impactfactor calculated 21,3 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 23 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 400V/3ph/50Hz/8A/4.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 24 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 25 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 400V/3ph/50Hz/8A/4.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 26 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 27 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 230-400V/3ph/50Hz/14.3-8A/4.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421564 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 28 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 29 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 400V73ph/50HZ/9A/5.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 30 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 31 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 400V/3ph/50Hz/9A/5.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 32 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 33 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 220,440V/3ph/60Hz/17-9A/5.7KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421564 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 34 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 35 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 220,440V/3ph/60Hz/17-9A/5.7KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421564 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 36 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 37 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 220-240V/1ph/60Hz/20A/2.15KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421565 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 38 DN8 x 15 m Hose Guaranteed sound power Impactfactor calculated Vibration ISO 5349, lance 1 / lan- 0 / - ce 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 39 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 115V/1ph/60Hz/20A/2.1KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421565 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 40 DN8 x 15 m Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 41 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 200V/3ph/20Hz/18A/5KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 2800 Pump revolutions 106421561 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 42 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 43 Full Ceramic Piston type Stroke Agip Rotra Pump oil type Pump oil amount ELECTRIC: 200V/3ph/60HZ/20A/5.8KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 3360 Pump revolutions 106421561 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 44 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 45 Piston type Stroke Agip Rotra Pump oil type 0,23 Pump oil amount ELECTRIC: 230V/1ph/50HZ/14.5A/3.4KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 1450 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 46 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 47 Piston type Stroke Agip Rotra Pump oil type 0,23 Pump oil amount ELECTRIC: 230V/1ph/50HZ/14.5A/3.4KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 1450 Pump revolutions 106421566 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 48 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 49 Piston type Stroke Agip Rotra Pump oil type 0,23 Pump oil amount ELECTRIC: 400V73ph/50HZ/8A/3.8KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 1450 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 50 HP Hose DN6x10 w/swivel, Quick 3/8",155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 51 Piston type Stroke Agip Rotra Pump oil type 0,23 Pump oil amount ELECTRIC: 400V/50HZ/8A/3.8KW Electric data V/ph/Hz/A/kW Control voltage Highvoltage (HV) test voltage HV Insulation resistance MΩ Earth circuit resistance Ω 1450 Pump revolutions 106421563 Electrical diagram no. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 52 HP hose DN6 15 for HW and w/swivel, 155° Hose Guaranteed sound power Impactfactor calculated 0 / - Vibration ISO 5349, lance 1 / lance 2 IPX5 Protection Class Machine incl. standard acc. 607x688x1000 Size - Machine alone L x W x H NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 53 Construction VARIANTS: Neptune 1 Single phase: 1-22 EU Neptune 2 Single phase: 1-22 EU, 2-25 GB, 2-26X GB, 2-26 EU, 2-26X EU, 2-26 SPECIAL EU, 2-26X SPECIAL EU. Three phase: 2-33 EU, 2-33X EU, 2-33 NO, 2-33X NO, 2-41 EU, 2-41X EU, 2-30 SPECIAL EU, 2-30X SPECIAL EU X vs.
  • Page 54 Water regulation. (Only Neptune 2) Outlet temperature sensor. Microswitch. Flow control. Unloader. Safety valve. NOTE: Neptune 1 is not equipped with water break tank and water regulation (steam device). Neptune 2 Special is not equipped with water regulation (steam device). NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 55 Instead of the water break tank a back flow preventer must be connected between the water supply and the machine. Delayed stop of the motor pump unit is not possible for the Neptune 1 due to increased by-pass pressure. Neptune 2 Special is not equipped with: Pos.
  • Page 56 12 kV high voltage for the electrodes. A spark is produced across the electrodes to ig- nite the fuel/air mixture. The exhaust sensor (6) controls the exhaust temperature and cuts of the machine when the temperature reaches 270 C. The switch (9) for exhaust sensor is placed in the E-box. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 57 Function Fig.D.5. Electric box NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 58 Function Schematic function Neptune 1. In this situation the position of the parts are The following: The none return valve( A) is closed by the spring (B) as there is no pressure on either of the sides. The easy start ball valve (C) is pressed against the upper seat by the easy start spring (D).
  • Page 59 Function Schematic function Neptune 1. The none return valve (A) is fully open because of full working pressure and flow. 2. The easy start ball valve (C) is pressed against the lower seat by the pressure from the pump. 3. The s/s spring is pressed a little , but the Activation arm (E) is still on the front position, The micro switch (F) at “switch on”...
  • Page 60 Function Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 61 Function Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 62 Function Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 63 Function Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 64 Function Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 65 Pressure outlet(5) Control piston(4) Non-return valve(7) Valve pressure(6) Piston(9) Easy start valve(8) ( Enabled) Inlet(11) Valve suction(10) Fig.D.6: Schematic drawing valve block 1 ~ Disabled in picture Fig.D.7: Valve block 1 ~ - Cut Away View NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 66 End switch(1) Pressure and water Dertergent valve(3) reduction valve(2) Pressure outlet(5) Control piston(4) Non-return valve(7) Valve pressure(6) Piston(9) Valve Suction (10) Inlet(11) Fig.D.8: Schematic drawing valve block 3 ~ Fig.D.9: Valve block 3 ~ Cut Away View NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 67 In the three phase version, fig.D.10.1 just has to be skipped. Colour code : Light blue - Vacuum Blue - Supply pressure Purple - Reduced pressure Red - High pessure Fig.D.10.1: Schematic function valve block Fig.D.10.2: Schematic function valve block NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 68 Non-return valve holds pressure in gun and releases pressure in valve block. and on top of control piston.Control Non return valve moves to its seat. piston moves down and end-switch cuts off motor power supply. Fig.D.10.5: Schematic function valve block NEPTUNE 1&2_EN_Ver.2.1_45/2014...

  • Page 69: Troubleshooting

    Troubleshooting Neptune 1&2. Trouble Shooting Cause Remedy Indication lights Ope- Ser- ration Fuel Scale vice Boiler Flame > Constant light Appliance ready for operation. > Flashing light Flow sensor fault. Water tap closed or water shortage > Refuel detergent or set SDR valve to Detergent tank empty “0”...
  • Page 70 Troubleshooting Neptune 1&2. Trouble Shooting Constant light > > Machine shuts down, Cold water operation possible Boiler overheated. Ex- > haust sensor Check water supply (EXT-H) has cut off fuel supply. Insufficient water flow > Clean boiler Machine scaled Boiler not serviced >...
  • Page 71 The pump is lubricated for life, therefore Check the fuel filter and replace if necessary.   regular oil change isn`t necessary. However, change the oil at major repairs.  Type of oil, refer to part ”B”.  NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 72 And remove the top bumper from the from the motor/pump unit. bottom bumper. Loosen the screws fixing the bottom bumper to the frame and pull the bumper out of the frame. Loosen the 4 screws fixing the motor cover to the bottom bumper. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 73 Suction valves - Plug kept in place between Inspect valves/seats and replace if   valve block and piston housing. necessary. Pull out the valves by means of a puller or a  nose pliers. Pressure valves - screw plug (17 mm  wrench). NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 74 By use of a combination pliers remove the   Fit screw plug applying Loctite 243. thrust collar.  Torque 44Nm (33ft.lbs). Beware not to damage the packing ring.   Inspect the seals and packings for wear and  replace them if necessary. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 75  Fig.F.19: Valve Block Fig.F.20: Thrust Collar Mounted - Cut Away View Use compressed air to clean relief bores. The cut-away view shows the right order for   the V-packing assembly. Refer to numbers on fig.F.26.  NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 76 Fig.F.24: Easy start valve - Check Dismount the plug with a 6mm hexagon key. Check the parts for wear and damages.   By assembly apply Loctite 243 Be aware of the order of the parts.   NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 77 Take out the valve seat by means of e.g. an  impact piercer (Fig.F.46. Control piston – Maintenance Fig.F.27: Puller—Impact piercer. Fig.F.28: Control piston– Dismount Remove the Start/Stop switch from the  connector. Unscrew the union nut using a 17 mm  socket. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 78 Let the oil drain out into a tray. Clean the wobble disc housing properly   Note housing position and the 2 O-rings! before assembly.  Beware of the springs being relieved. Use paper - not cotton waste   NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 79 Fig.F.36: Oil Seal Mounting Toool Fig.F.35: Oil Seal - Replacement Using the proper tool, fig.F36 carefully tap In lack of this tool, use a socket from a   the new oil seal in place. socket wrench set. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 80 Fig.F.40: Pump– Blow through. Use Loctite 243 on the center screw and tigh-  ten it with a torque setting at 24 Nm (18 ft.lbs.). When tightening up the center screw, hold  the motor shaft with a 16mm spanner. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 81  oil. note the correct order at assembly. Refer to part ”B” and refill with correct  asured amount of oil. Mount the oil plug extension.  Now the motor and the valve block can be  assembled. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 82 Fig.F.45: Pump unit complete The function of the Neptune 2 Special pump is similar to the Neptune 2 pump. The assembling and disassembling of the pump parts must be made after the same principles. Follow the torque specifications by assembling. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 83 Service / Repair Neptune 1 Fig.F.46: Motor/pump unit complete NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 84 Service / Repair Neptune 1 Motor cover Fig.F.47: Neptune 1 pump Fig.F.48: Neptune 1 pump is placed in the buttom cabi- To repair plungers/seals the MP-unit has to  net part. be lifted out of the frame. Remove the motor cover.
  • Page 85 Service / Repair Neptune 1 Micro switch Fig.F.51: Micro switch box Fig.F.52: Micro switch arm Remount the micro switch box. Press down the micro switch arm with a screwdriver. Valves Fig.F.53: Seat for pressure valve Fig.F.54: Seat for pressure valve...
  • Page 86 Service / Repair Neptune 1 Fig.F.55: Suction valves Fig.F.56: Suction valves Remove the valve seats using a threaded pin Mount new valves with a slight finger pressure or similar tool. Discard the valve seats. and special tool no.1220103 Torque Use loctite 271— torque 20 Nm...
  • Page 87 Service / Repair Neptune 1 Easy start valve Fig.F.58: Easy start valve Fig.F.59: Seat for easy start valve Remove the seat for easy start valve with a The slit in the easy start seat ensure the pres- small hook. Then remove the o-ring under- sure drop from pump outlet to pump inlet, neath the seat with a small screwdriver.
  • Page 88 Service / Repair Neptune 1 Cylinder head Wobble disc & Bearing Fig.F.62: Cylinder head Fig.F.63: Wobble disc Tip up the oil seal with a screwdriver and Inspect the wobble disc and pistons for dama- discard. ges and replace if necessary.
  • Page 89 Caution ! On capacitor might the wiring diagram inside.  1 ~ machines still be charged ! The components in the E-box are shown by numbers in the wiring diagrams chapter H. Fig.F.69: Electrical box - Exploded view. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 90 Loosen the nut and drag out the sensor. C heck resistance.   Disconnect the plug on the cord and replace E mpty tank - open.   the sensor if necessary. F ull tank - closed.  NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 91 However there are used variants of the fuel nozzles and air distributers. 1. Ignition Transformer 2. Ignition cords. 3. Ignition electrodes 4. Flame sensor. 5. Fuel nozzle. 6. Air distributer. Fig.F.74: Distributer Fig.F.75: Fuel nozzle. Fig.F.76: Fuel nozzle. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 92 Service / Repair Burner Unit. Fig.F.77: Burner unit. Fuel solenoid Fuel pump Burner motor Burner housing Fuel filter Fan cover NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 93 Fig.F.79: Heating coil. Fig.F.80: Heating coil. Begin mounting the cord at the position shown Continue to mount the cord until tube crossing on picture counter clock wise (straight arrow) of inner and outer tube, see arrow on picture NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 94 Turn round so the direction for mounting is Continue mounting the cord clockwise now clock wise Fig.F.83: Heating coil. Fig.F.84: Heating coil. Continue mounting the cord until the arrow on The final result picture. App. Thread length is 160-170 cm. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 95 The exhaust temperature sensor is fitted with If the exhaust temperature reaches 270C the  2 screws in the exhaust. machine cuts out. The relay placed in the E- box can be reset by pressing the green button. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 96 R emove the water hose from the tank.  R emove the water break tank from the machi-  Fig.F.89: Water break tank. R emove Remove the remaining hoses from  the tank. C heck float valve and replace if necessary.  NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 97 To release the right-hand side of the drum, To take the drum apart, the four screws, two   press the two locks ( arrow fig.F.64). on either side have to be removed. The drum can now be lifted out from frame.  NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 98   Inspect o-rings on the end-piece and replace To ease assembly, use a combination pliers   if necessary. to hold the lock bracket. Grease the o-rings before assembly.  Lock Fig.F.98: Hose Reel - Exploded View NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 99 Run the machine to check correct adjustment.  ned back to the starting point. The reed switch on the flow switch housing  must be pushed ALL THE WAY UP, before the two screws are tightened. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 100  Counter clockwise for lower cut-off pressure. The reed switch on the flow switch housing   Tighten the counter nut after adjustment. must be pushed ALL THE WAY UP, before  the two screws are tightened. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 101 The air flap on the side of the burner fan is   A djust the fuel pressure according to the va- adjusted by a self-locking spindle on a set  lues in Technical data chapter A. screw. Turning clockwise increases the air intake, turning counterclockwise reduces it. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 102 The stored value is displayed at the led’s and they are flashing. Switch the machine off with S1 (main switch). Remove the jumper from JP2. Service Time Operation Fuel Anti Stone Service Boiler Service Flame Sensor 100h 200h 300h 400h regardless ON/OFF 500h (EXH-T) Fig.G.13: LED lights. NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 103 7 The new K1 / K2 delay time is now stored in the EEProm. The stored value is displayed at the led's and they are flashing. 8 Switch the machine off with S1(main switch). 9 Remove the Jumper at JP6 Fig.G.14: K1 & K2 delay time. NEPTUNE 1&2_EN_Ver.2.1_45/2014...

  • Page 104: Wiring Diagrams

    Wiring diagrams Neptune 1 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 105 Wiring diagrams Neptune 2 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 106 Wiring diagrams Neptune 2 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 107 Wiring diagrams Neptune 2 NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 108 Notes NEPTUNE 1&2_EN_Ver.2.1_45/2014...
  • Page 109 NEPTUNE 1&2_EN_Ver.2.1_45/2014...

This manual is also suitable for:

Neptune 2Neptune 2 special

Table of Contents