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NEPTUNE PE/DE Service Manual NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Safety instructions Technical data 6 - 9 Construction 10 -17 Function 18 -37 Troubleshooting 38 -41 Service / Repair 42-62 Adjustment / Test 63-71 H. Wiring diagrams 72-92 Jetwash Direct ltd...
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-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 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Preface 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.
Before using the cleaner, al- ways read the operating instructions and keep them readily available. Repair work should be carried out by persons instructed and trained in repairing this product. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Effect 1000 RPM @ HP and Boiler 2825 PUlley Size SPZ 63/1 Belt dimension Motor/Gen. SPZ 670 Length 1130 Width Height 1050 Weight Sound power level CE, Lwa High-pressure hose DN10 HP nozzle 0640 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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NA5 pump Honda motor 230V Generator 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 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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NEPTUNE PE/ NEPTUNE 7-61PE, front side hole in the fuel tank. DE machines Water outlet Honda Motor C3 pump Water Break tank, OPTIONAL Water regulator Anti Scale container, OPTIONAL Wheels, OPTIONAL NEPTUNE 7-61PE, front side NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Construction Overview NEPTUNE 7-61PE NEPTUNE 7-61PE, boiler top Flow- Flow- Temperature Temperature sensor, Flame sensor switch switch Sensor boiler exhaust Electrodes Fuel nozzle NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Construction Overview NEPTUNE 7-61PE NEPTUNE 7-61PE, backside Generator, 230V Charging relay Top cover NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Temperature sensor—pump Safety valve. (This safety valve is used only on 5- 85PE and 5- Oil glass Water Unloa- 51DE, becasue w/level inlet the unloader does switch not have a safety valve). Generator Battery—12V NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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230V motor Temperature sensor exhaust Temperature sensor water outlet Safety valve (only on 5-51DE & 5-85DE) Flow switch 1 and 2 Unloader & water regulator NP5 pump Oil container w/level switch Thermal dump valve NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Mitsubishi motor Oil container w/level sensor Temperature By-pass valve C3 pump sensor—pump w/ water regu- Temperature sensor lator exhaust Temperature sensor water outlet Flow switch 1 and 2 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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(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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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(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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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.
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Pos. 4: Fuse—Self-resetting ”Pico fuse” Arrow 1 Pos. 5: Fuse Setting is WITHOUT JUMPER = By-pass time Pos. 6: Fuse active Arrow 2: Setting is JUMPER MOUNTED ON PIN 2 AND 3 = Flame Sensor active. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Function NEPTUNE PE/DE—NP5 PUMP The 3piston radial pump NP5 is used in the NEPTUNE 5-85PE and 5-51DE Cam shaft Pressure valve Shaft Suction valve The three pistons are driven by the motor via a belt drive. The cam shaft transforms the rotation power into the pistons reciprocating movements.
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Function NEPTUNE PE/DE—NA5 PUMP The 3piston NA5 pump is used in the NEPTUNE 5-46PE and 5-54PE Honda motor and D-bearing cover Pistons, cylinder block,cylinder head and sealings Water inlet By-pass valve with water re- gulator The NA5 pump is connected to the Honda motor with a direct drive.
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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.
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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”. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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The pressure ”K” will fall depending of the size of the opening in seat ”H”. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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25-30 bar “E”, because the piston “C” is fixed to above normal working pressure). Now the valve cone. the valve cone “D” lift from its seat “E”, and water runs in by-pass. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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(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. Unloader disassembled NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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.
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Function Heat exchanger NEPTUNE PE The heat exchanger is the func- tional link between the heating sub- system and the water subsystem. In "Hot water" mode the burner fan (1) draws in air and conducts it lat- erally into the heat exchanger...
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The flame sensor is a light-sensitive phototransistor. The flame sensor checks for the presence of a flame. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
Service interval: service flashes. Service machine. due in 20 hours. "Hot water" and "Cold water" mode is possible. • ⇒ illumina- Service interval elapsed. Service the machine. tes. "Hot water" and "Cold water" mode is possible. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Tighten the screws, re- ⇒ Detergent tank empty. place the HP hose or ⇒ Filter clogged in water pipe. intake. • Refill detergent. ⇒ HP pump sucking in air. • Clean the filter • Correct leaking points. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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See Chapter F.2.6 and Green system, burner fault. F.7. "Cold water" mode flashes slowly & is possible. flashes ⇒ • fast Flame probe (option) If this option is fitted, re- sooted up. move it and clean it. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Take tank 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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Service / Repair NA5 Pump NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Knock carefully on the back side of the adequate screwdriver and replace them. Be valve seat to demount it or use an 8mm careful not to scratch the surface. threaded pin and pull it out. • Replace with new parts. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Take out the pressure valve seats with out of the cylinder head. an adequate puller or use an 8mm • Replace with new parts if necessary. threaded pin. • Replace with new parts if necessary. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Place sleeves, pistons and springs as sleeves with soapy water. shown. • • Mount the sleeves using a 19mm box Mount the cylinder block to the D-bearing spanner and a fiber hammer. cover by the two 6mm mounting screws. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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6mm bolt into the threads. Tighten the be kept in the right position in proportion bolt against the motorshaft and pull the to the stator. wobble disc out. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Motor by four 6mm bolts. be demounted carefully using a • When the bearing is damaged, always screwdriver. • replace the complete D-bearing cover. Mount the oil sleeve by using an adequate box spanner and a fiber hammer. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Service / Repair C3 Pump NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Service / Repair C3 Pump Mandrel no.: 1216506 NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Mount new O-rings on studs with tool no. 1206812. Spacer ring Always replace secondary sleeves when replacing pressure sleeves. Check that there is a free passage from the drain holes. Secondary sleeve Back-up ring O-ring NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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(rides on wobble disc) or oil sleeves. Check the ceramic for cracks. Remo- ve any coating. Pressure area, Ceramic touches Stainless steel the bearing disk NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Check the bearing surfaces for wear. As circlip on the rotor shaft. Refill with 1 l oil long as the wear is even and shiny without type Castrol Alphasynt ISO 150. pittings or grooves, the wobble disc can be NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Service / Repair NP5 Pump Valve cover & seals. Motor Pistons & oil seals. Pump h ousing NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Inspect the the thrust collar for marks, When you mount the cylinder head lubricate and mount it with your fingers. tighten the bolts in the shown sequence Use a 6mm hexagon wrench. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Service / Repair NP5 Pump NP5 Unloader valve NP5 Unloader valve NP5 Unloader valve parts NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Exhaust Flame sensor Electrodes Fuel nozzle Water outlet Water inlet Top plate Air distributor Flame tube top part Burner tube Flame tube Air inlet Fixation spacer Outer jacket Inner jacket Mounting plate Insolation NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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"Arrows"and hook up the crane and lift out the coil. Burner Unit. Fuel solenoid Fuel pump Burner motor Burner housing Fuel filter Fan cover Clean up deposits and change the isolation if needed. Burner fan and fuel pump. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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The electrode 18 is self adjusting the position on the nozzle by a spring washer 19 under the fixing screw 20. 5 mm The flame sensor 9 must be fixed with 5 in the right position. Clean the flame sensor NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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After the first 50 required months or Weekly operating hours 500 operating hours Water filters Oil filter Checking the pump oil quality Changing the pump oil Emptying the fuel oil tank NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Fig.G.01: Wobble disc Fig.G.02: Cylinder block 65 Nm 25 Nm Fig.G.03: Cylinder head Fig.G.04: Venting valve 10 Nm By hand Fig.G.05: By-pass housing Fig.G.06: Venting valve 40 Nm 40 Nm Fig.G.07: Outlet fittings Fig.G.08: Water regulation NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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 tech- nical data sheets chapter B. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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(go into bypass). Then you adjust the ad- justing “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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Allen Key the following way. sure adjustment bolt. Use a 13 Start machine with correct HP nozzle. mm. box spanner. Loosen unloader until pressure drops, then turn ½ turn clockwise, to obtain full pressure again. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Now the correct adjust- justed, tighten the lock nut with a ment of the unloader is done. By 13 mm. Box Spanner. turning the handle counterclock- wise, you can reduce the pump water volume and pressure. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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The air flap on the side of the burner fan is • Adjust the fuel pressure according to the adjusted by a self-locking spindle on a set values in Technical data chapter A. screw. Turning clockwise increases the air intake, turning counterclockwise reduces it. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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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. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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Adjustment / Test Boiler Fig.F.49. Boiler top Heating system - Overview. 1. Ignition Transformer. 4. Flame sensor. 2. Ignition cords. 5. Fuel nozzle. 3. Ignition electrodes 6. Air distributer. Fuel nozzle. Fuel nozzle. NEPTUNE PE-DE_en_Ver.1.0_October 2010 Jetwash Direct ltd...
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