Nilfisk-ALTO NEPTUNE 4 FA Service Manual
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Nilfisk-ALTO NEPTUNE 4 FA Service Manual

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NEPTUNE 4 FA
Service Manual
Item nr 107146560
Version 02– 22– 2011

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Summary of Contents for Nilfisk-ALTO NEPTUNE 4 FA

  • Page 1 NEPTUNE 4 FA Service Manual Item nr 107146560 Version 02– 22– 2011...
  • Page 2 Repair manuals and ”Technical Service Bulletin” sheets should be available at the site where repairs are carried out. It is not permitted to give them to third parties. Use original Nilfisk-ALTO spare parts only. NEPTUNE FA_EN_Ver.2.0_ 22/11...

  • Page 3: Table Of Contents

    Index Safety Instructions ..............4 Technical Data ................ 5 Construction ................. 17 Side view ..............17 Top view ............... 17 Frame and cabinet ............18 Operation panel ............19 Panel—inside..............19 Electrical box ..............19 PCB A1 ................. 20 Boiler ................21 Motor - Pump unit ............

  • Page 4: Safety Instructions

    Safety instructions For your own safety Observe valid safety regulations for electrical equipment. In particular, observe the following regulations: IEC 60335-2-79 EN 60335-2-79 Additionally: Also see national regulations Before using the cleaner, always read the operating instructions Repair work should be carried and keep them readily available.
  • Page 5 Technical data NEPTUNE 4 FA Gen. 4-43FAX EU 4-50FA EU Description Tol. 4-39FAX EU 400/3/50/ 400/3/50/16 400/3/50/13 Item no. 107146600 107146601 107146602 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 6 Technical data NEPTUNE 4 Gene- 4-39FAX EU 4-43FAX EU 4-50FA EU Description Tol. 400/3/50/ 400/3/50/16 400/3/50/13 Item no. 107146600 107146601 107146602 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...

  • Page 7: Technical Data

    Technical data NEPTUNE 4 FA Gen. 4-28FAX Expt 4-25FAX EU Description Tol. 220/1/60/15 230/1/50/16 4-44FA JP 200/3/50/23 Item no. 107146605 107146608 107146609 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 8 Technical data NEPTUNE 4 Gene- 4-28FAX Expt 4-25FAX EU 4-44FA JP Description Tol. 220/1/60/15 230/1/50/16 200/3/50/23 Item no. 107146605 107146608 107146609 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...
  • Page 9 Technical data NEPTUNE 4 FA Gen. 4-50FAX EU 4-50FA NO Description Tol. 4-44FA JP 200/3/60/20 400/3/50/13 400/230/3/50/ Item no. 107146610 107146611 107146612 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 10 Technical data NEPTUNE 4 Gene- 4-44FA JP 4-50FAX EU 4-50FA NO Description Tol. 200/3/60/20 400/3/50/13 400/230/3/50/ Item no. 107146610 107146611 107146612 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...
  • Page 11 Technical data NEPTUNE 4 FA Gen. 4-50FAX NO 4-55FA EU 4-55FAX EU Description Tol. 400/230/3/50/ 400/3/50/14 400/3/50/14 Item no. 107146613 107146614 107146615 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 12 Technical data NEPTUNE 4 Gene- 4-50FAX NO 4-55FA EU 4-55FAX EU Description Tol. 400/230/3/50/ 400/3/50/14 400/3/50/14 Item no. 107146613 107146614 107146615 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...
  • Page 13 Technical data NEPTUNE 4 FA Gen. 4-55FA Expt 4-55FAX Expt 4-36FAX USA Description Tol. 220/440/3/60/23/14 220/440/3/60/23/14 230/1/60/30 Item no. 107146616 107146617 107146618 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 14 Technical data NEPTUNE 4 Gene- 4-55FA Expt 4-55FAX Expt 220/440/3/60/23/1 220/440/3/60/23/1 4-36FAX USA Description Tol. 230/1/60/30 Item no. 107146616 107146617 107146618 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...
  • Page 15 Technical data NEPTUNE 4 FA Gen. Description Tol. 4-28FA Gerni 240/1/50/15 4-50FAX Gerni 400/3/50/ Item no. 107146619 107146620 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Pump-Data Max. inlet pressure (bar) Max. Inlet temperature (°C)
  • Page 16 Technical data NEPTUNE 4 General 4-28FA Gerni 4-50FAX Gerni Description Tol. 240/1/50/15 400/3/50/ Item no. 107146619 107146620 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12° (°C) +4 / +4 / Delta temp.
  • Page 17 Technical data NEPTUNE 4 FA Gen. 4-50FA Expt 4-55FAX EU Description Tol. 220/440/3/60/ 4-39FAX EU 400/3/50/ 400/3/50/14 Item no. 107146622 107146625 107146626 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -...
  • Page 18 Technical data NEPTUNE 4 Gene- 4-50FA Expt 4-39FAX EU 4-55FAX EU Description Tol. 220/440/3/60/ 400/3/50/ 400/3/50/14 Item no. 107146622 107146625 107146626 Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. - Technical Data Heating Unit Boilerpower_input (kW) Temperature t max, @ inlet 12°...

  • Page 19: Construction

    Impact = Q1 x √ P1 x 0.24 [ N ] P1 = bar. Q1 = l/min.v P1. FA: Flow activated start/stop system The Neptune 4 FA is build with an NA5 pump. The by-pass system is flow activated, unlike the pressure activated by-pass system known from previous Neptune machines.

  • Page 20: Frame And Cabinet

    Construction Lance holder Handle Top cover Fuel filter Side cabinet—right Side cabinet—left Fuel tank Detergent tank Water break tank External deter- gent Fig.C.3: Frame & cabinet parts NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...

  • Page 21: Operation Panel

    Construction The electric box (Fig.C.6) contains the control board, the transformer, relays, fuses,and connection terminals. The cover plate is mounted with the main switch, the temperature adjustment and five status/warningLights (Fig.C.4). The cover is sealed around the edge and around the manometer and the detergent valve. Operation Pump oil Service...

  • Page 22: Pcb A1

    (contactor, relay, solenoid valve, anti stone pump) with 24V AC. The transformer T1 supplies the system with 24V and 8V AC. X2 is the connector to the Nilfisk-Alto Datalogger and the service setting jumper. Detailed function is described in chapter D.

  • Page 23: Boiler

    Construction 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.

  • Page 24: Motor - Pump Unit

    Construction Fig.C.9: Motor - Pump unit The NA 5 three piston axial pump used in Neptune 4 FA is build in line with the electrical motor as one compact unit. Fig.C.10: By-pass valve Fig.C.11: Flow control The start/stop system in Neptune 4 FA is flow The flow control checks if there is flow in the Activated.

  • Page 25: Function

    Function If the machine and the power supply are working correcdtly the following will happend during start Start - cold Start - hot Status indicators Detergent valve Fig.D.1: Display The main switch (S1; functions: on/off/temperature setting) is turned to "Cold water" mode. AC vol- tage is applied across the main switch (S1) to the control transformer (T1).
  • Page 26 Function If the main switch (S1) is set to "Hot water" mode with the spray device open, and the required tem- perature is subsequently preset with the same switch, if the temperature sensor (B1) is within set limits, if the level sensor (B9) signals that there is sufficient fuel in the tank and the flow indicator (B2) determines adequate volume flow in the system, the processor turns on the burner motor (M2), the anti scale pump (Y3) and the ignition transformer (T2) across the burner relay (K2).

  • Page 27: Hot Water Function

    Function The heat exchanger is the functional link between the heating subsystem and the water subsystem. In "Hot water" mode the burner fan (1) draws in air and conducts it laterally into the heat exchanger where it is routed upwards between the two jackets to the air distributor (2). This preheats the air before it mixes with the fuel spray from the fuel nozzle (3).

  • Page 28: Sensors And Actors

    Function Fig.D.3: Sensors & actors Sensors: B1: Temperature sensor in the outlet from the boiler. Controls the combustion (Y1 on/off) according to setting. B2: Flow switch senses the flow out of the pump into the boiler and controls solenoid Y1 on/off. B3: Safety thermal switch placed in the exhaust of the machine, if temperature >...

  • Page 29: Motor/Pump

    Function Fig.D.4: Motor/pump Stator. Suction valve. Rotor. Pressure valve. Wobble disc. BY-pass housing Ceramic piston. Water regulation valve The three ceramic pistons ”D” are driven by a wobble disc ”C”, the mission of which is to transform the rotating power from the rotor ”B” into the reciprocating pumping pistons ”D”. The angle of the wobble disc ”C”...

  • Page 30: Working/By-Pass Pressure

    Function Fig.D.5: Working pressure 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”...

  • Page 31: Water Reduction

    Function Fig.D.7: By-pass pressure The by-pass pressure is determined of the spring tension in valve ”A”. The tension is fixed and will bring out a by-pass pressure in about 30 - 35 bar. Valve ”A” also secures the self suction ability. The cut off pressure when the gun is released, is determined of the adjustment screw ”B”.

  • Page 32: Flow Control

    Function Hose connection/valve seat. Non return valves. Inlet for water from water supply. Magnet piston for reed switch E Reed switch for start of motor/pump. Water inlet from pump. Non return valve/magnet piston for H Reed switch for start of heating system.

  • Page 33: Troubleshooting

    Constant light  Fuel shortage  Top up fuel Cold water operation is possible Flashing light   Top up Nilfisk-ALTO AntiStone Nifisk-ALTO AntiStone shortage Constant light  Service interval has expired  Contact Nilfisk-ALTO Service Flashing light  Service interval due in 20 hours ...
  • Page 34  Remove/disconnect extension cable  Possible phase failure; have electrical connection checked  Machine overheated  Contact Nilfisk-ALTO Service Flashing light  Flame sensor sooted  Clean flame sensor  Ignition or fuel system failure  Contact Nilfisk-ALTO Service...

  • Page 35: Boiler Performance

    Troubleshooting Boiler performance The symptom is reduced performance of the pump effect or the boiler effect. The symptom of reduced boiler effect is a lower water outlet temperature than the set value. The possible causes for this are as follows: Fault Cause Remedy...

  • Page 36: Service / Repair

    Service / Repair Observations Fig.F.01: Data Plate Fig.F.02: Water filter—Cleaning   Prior to any maintenance, identify the As required clean the water filter.  machine version at the data plate. Unscrew connector for water break tank.   The data plate is situated in two places at the Pull out the filter by use of a nose pliers.

  • Page 37: Electrical System - Maintenance

    Service / Repair Electrical system - Maintenance Fig.F.05: Electrical box Fig.F.06: E box knob disassembly   Caution ! Before any repair on the electrical Loosen the screw in the bottom of the knob.  system - Pull out the power plug ! Drag the knob out from the shaft.

  • Page 38: By-Pass System

    Service / Repair By-pass system 1210558 Fig.F.10: By-pass - valve cone. By reassembling of the valve cone inside the water regulation, special tool no 1210558 can be used. Fig.F.09: By-pass—water regulation. By assembling and disassembling of the parts in the by-pass system be aware of the order of the components.

  • Page 39: Valves

    Service / Repair Valves Fig.F.12: Valve housing Fig.F.13: Thrust collar   Dismount the valve housing from the Be carefull not to damage the surface cylinder block by the three M12 bolts. inside when dismounting the thrust collar.   Be aware of the o-rings and valve parts.
  • Page 40 Service / Repair Valves Pic. F.16: Suction valves Pic. F.17: Pressure valves   Overview of the placement of suction valve Overview of the placement of pressure parts. valve parts Picture of piston guides Fig.F.18: Pressure valves Fig.F.19: Pressure valve seat ...

  • Page 41: Cylinder Block

    Service / Repair Cylinder block Fig.F.20: Cylinder block Fig.F.21: Oil Sleeves   Overview of the placement of the parts in Take out the oil sleeves using an the cylinder block. adequate puller.  Be careful not to damage the surface of the cylinder block.
  • Page 42 Service / Repair Replacement of secondary seals and header ring Pic.9. Showing the right position of the header ring. Knob on header ring must be placed in groove against the centre of the cylinder head. Fig.F.24: Header ring If the header ring is mounted wrongly and not according to instruction, there is a big risk of damaging the header ring and parts of it will block pistons and valves in the pump or get stucked in the non return valve in the unloa-...

  • Page 43: Wobble Disc System

    Service / Repair Wobble disc Fig.F.26: Pump head Fig.F.27: D-bearing cover and wobble disc   The cylinder head and the cylinder block Overview of the parts inside the D- is fastend to the D-bearing cover by two bearing cover. 6mm mounting bolts for the cylinder block and three 12mm bolts for the cylinder head.

  • Page 44: Bearing System

    Service / Repair Bearing system Fig.F.30: Bearing track removal Fig.F.31: Bearing system & woble disc   Remove bearing track in D-bearing cover. Replace the complete wobble disc system and make sure parts are as sembled according to instructions Fig.32 &...

  • Page 45: Electrical Motor

    Service / Repair D-bearing cover Fig.F.34: D-bearing cover Fig.F.35: Oil sleeve   The D-bearing cover is mounted to the The oil sleeve in the D-bearing cover can Motor by four 6mm bolts. be demounted carefully using a  When the bearing is damaged, always screwdriver.

  • Page 46: Fuel Tank

    Service / Repair Fuel tank. Heating system. Fig.F.49. Boiler top Fig.F.38: Fuel tank - Overview. 1. Fuel tank. 2. Strainer. 3. Float valve 4. Gasket. Fig.F.39: Heating system - Overview. 1. Ignition Transformer 4. Flame sensor. 2. Ignition cords. 5. Fuel nozzle. 3.

  • Page 47: Exhaust Temperature Sensor

    Service / Repair Exhaust temperature sensor. Fig.F.42: Temperatur sensor. Fig.F.43: Temperatur relay.  The exhaust temperature sensor is fitted with If the exhaust temperature reaches 270°C 2 screws in the exhaust. (518°F) the machine cuts out. The relay pla- ced in the E-box can be reset by pressing the green button.

  • Page 48: Heat Exchanger

    Service / Repair Heat exchanger Fig.F.45: Dismounting coil Fig.F.46: Dismounting coil Remove the outer top cover and mount the Attention : Be aware of the fact that the machi- lifting tool over the two coil ends and fix it with ne can tip over.

  • Page 49: Torque Specifications

    Adjustment / Test Torque specifications 20 Nm 20 Nm 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 4 FA_EN_Ver.2.0_ 22/11...

  • Page 50: Adjustment Of By-Pass System

    Adjustment / Test Adjustment of by-pass system. Fig.G.09: Pressure gauge Fig.G.10: Test tap Connect test pressure gauge 1206358 to the Machines with hose reel: machine water outlet. Connect extension hose 301001311and test pressure gauge 1206358 to the machine water outlet Fig.G.11: Safety valve Fig.G.12: Pressure bolt Check the working pressure in data sheets...
  • Page 51 Adjustment / Test Fig.G.13: Pressure bolt Fig.G.14: Safety valve When adjustment is done, lock the bolt with Let the machine run 5 bars lower than the cut the counter nut. off pressure (working + adjustment) and adjust NOTE: If the cut off pressure is adjusted too the safety valve out (Counter clockwise) until it high >...

  • Page 52: Burner Settings

    Adjustment / Test Burner settings. Note: Higher CO2 concentrations at different barometric pressure, altitude or temperature and poor quality of the used fuel can lead to faster soot deposition on the heating coil of the heat exchanger. Preparation 1. Set the fuel pressure. 2.
  • Page 53 Adjustment / Test Burner settings. Fig.G.17: Soot raiting Fig.G.18: Burner measurements. Determine the soot rating with a soot pump (1) The CO2 content in the exhaust, the intake and soot rating reference scale. The figure and exhaust temperature are determined. This should not exceed "1".

  • Page 54: Electric Settings

    Adjustment / Test Electronic settings. Fuel LED Anti Scale LED Service LED Pump oil LED Operation LED Service jumper 301001873 Fig.G.20: Electronic adjustment. Setting possibilities: BR1 (1): this can be used to eliminate the pump bypass time of 20 seconds. - With jumper: bypass time active - Without jumper: bypass time eliminated...

  • Page 55: Wiring Diagrams

    Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 56 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 57 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 58 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 59 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 60 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 61 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 62 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...
  • Page 63 Wiring diagrams NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...

  • Page 64: Notes

    Notes NEPTUNE 4 FA_EN_Ver.2.0_ 22/11...

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