Service Manual: Neptune 4 Fa

NEPTUNE 4 FA
Service Manual
Item nr 107146560
Version 02– 22– 2011
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Preface
This service manual contains detailed description of the main repair work on the hot HPW
NEPTUNE 4 FA.
Repair work requires a suitable testing workplace with the necessary water and power sup-
ply.
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 troubleshooting.
Refer to the illustrated spare parts lists during repairs. They show the assembly position and
the sequence in which the individual components should be assembled.
See ”Technical Service Bulletin” (TSB) sheets—

Previously called ”Service Technical Information” (STI). They include information on technical
modifications that have been made after this repair manual was printed.
”Technical Service Bulletin” sheets are also valid as a supplement to the spare parts list until
publication of a new edition.
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 2

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 ......................................................... 22
By-pass valve ............................................................... 22
Flow control .................................................................. 22
Function ................................................................................ 23
Display .......................................................................... 23
Hot water function......................................................... 25
Sensors and actors....................................................... 26
Motor/pump................................................................... 27
Working pressure.......................................................... 28
By-pass pressure.......................................................... 28
Water reduction ............................................................ 29
Flow control .................................................................. 30
Troubleshooting ................................................................... 31
Boiler performance ....................................................... 33
Service / Repair .................................................................... 34
Observations................................................................. 34
Oil maintenance............................................................ 34
Fuel filter ....................................................................... 34
Electrical system - Maintenance ................................... 35
By-pass system ............................................................ 36
Valves ........................................................................... 37
Cylinder block ............................................................... 39
Wobble disc system...................................................... 41
Electrical motor ............................................................. 43
Fuel tank ....................................................................... 44
Heating system ............................................................. 44
Exhaust temperature sensor......................................... 45
Burner unit .................................................................... 45
Heat exchanger ............................................................ 46
Torque specifications.................................................... 47
Adjustment of by-pass system ...................................... 48
Burner settings.............................................................. 50
Electric settings……………………………………………..52
Service time settings..................................................... 52
Wiring diagrams ................................................................... 53
Notes ..................................................................................... 62
NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 3

Safety instructions A
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

Repair work should be carried read the operating instructions
out by persons instructed in and keep them readily available.
electrical installations or by
trained electricians only. Only allow the high pressure
cleaner to be used by persons
who have been trained in its use
and who have been explicitly
authorized to use it.
ESD measures Take the following ESD precautions before carrying out any
(electrostatic discharge) repairs to the electronics:
 Touch the earth conductor before repairing the cleaner

( to discharge electrostatic charge from your body ).
 Wear wrist band if necassary.
 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 ).

Technical data B
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
Technical Data Test Result Tol. + Tol. - Test Result Tol. + Tol. - Test Result Tol. + Tol. -
Pump-Data
Max. inlet pressure (bar) 10 10 10
Max. Inlet temperature (°C) 40 40 40
5,50
Pressure at pump head % 152 +8 / -8 166 +9 / -9 175 +10 / -10
5,50
Pressure @ Cylinder Head (bar) % 158 +9 / -9 172 +9 / -9 181 +10 / -10
5,50
Pressure @ Outlet (bar) % 140 +8 / -8 160 +9 / -9 163 +9 / -9
5,50
Pressure @ after Gun (bar) % 126 +7 / -7 138 +8 / -8 142 +8 / -8
Pressure cut off @ Cylinder Head
(bar) 178 +5 / -5 192 +5 / -5 201 +5 / -5
Pressure Pmax safety valve 250 +5 / -5 250 +5 / -5 250 +5 / -5
2,90
Flow. Qiec (l/min) % 11,55 +0,3 / -0,3 12,20 +0,4 / -0,4 13,70 +0,4 / -0,4
Flow. Qmax (l/min) 5% 12,50 +0,6 / -0,6 13,10 +0,7 / -0,7 14,60 +0,7 / -0,7
3,00
Flow. Qmin, steam (l/min) % 6,00 +0,2 / -0,2 6,50 +0,2 / -0,2 7,00 +0,2 / -0,2
Type NA5 NA5 NA5
Piston type Ceramic Ceramic Ceramic
Piston diameter (mm) 20 20 20
Stroke / Wobble disc angle 8,7 9,15 10,2
Oil BP Energol GR-XP Oil BP Energol GR-XP Oil BP Energol GR-XP
Pump oil type 220 220 220
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 400V/3~/50Hz 400V/3~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 9,2 +1,0 / -3,0 9,7 +1,0 / -3,0 12,2 +1,0 / -3,0
Current consump. - cold (A) 10 +1,0 / -3,0 10,5 +1,0 / -3,0 12,5 +1,0 / -3,0
Power Consumption - hot (kW) -
hot 4,7 +0,5 / -0,5 5,2 +0,5 / -0,5 6 +0,5 / -0,5
Fuse size (A) 16 16 16
Cord type H07RN-F 3G1,5 x 6m H07RN-F 3G1,5 x 6m H07RN-F 4G1,5 x 6m
Plug type CEE7 / 16A Schuko CEE7 / 16A Schuko CEE 3P+N+G / 16A
Control PCB PCB PCB
Control voltage 24 Volt-Control voltage 24 Volt-Control voltage 24 Volt-Control voltage
Contactor 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW
Electrical diagram 106427170 106427170 106427170
Eletrical test data
Highvoltage (HV) test (V) 1000 Vac 1000 Vac 1000 Vac
HV-Resistance (MΩ) ≥ 1MΩ / 500Vdc ≥ 1MΩ / 500Vdc ≥ 1MΩ / 500Vdc
Cord-resistance (Ohm) 0,20 0,20 0,20
Motor-Data
Motortype 3~ Induction 3~ Induction 3~ Induction
Rotational speed [min-1] 1450 1450 1450
Insulation Class F Class F Class F
Protection Class IP54 IP54 IP54
Nominal power [kW] 4 4 5,5
Cos j 0,75 0,75 0,75

Technical data B
NEPTUNE 4
Gene-
ral 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
Heating Unit
Boilerpower_input (kW) 61 61 66
Temperature t max, @ inlet 12° (°C) 82 +4 / -4 78 +4 / -4 76 +4 / -4
Delta temp. variance at 50 °C, meassured at
@ gun (°C) 30 +0 / -3 30 +0 / -3 30 +2 / -3
Boiler on time at 50 °C set point, @ inlet 12°
(sec) 30 +0 / -3 30 +0 / -3 30 +5 / -5
Steam temperature t II @ outlet and v.
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
Pressure P2 @ outlet v. standard nozzle
(bar) 27 +5 / -5 27 +5 / -5 27 +5 / -5
Fuel pump type Diesel Diesel Diesel
Oil pressure ( bar ) 12 +0,5 / -0 12 +0,5 / -0 14 +0,5 / -0
Nozzle size, oil 1,25 60°H (61659) 1,25 60°H (61659) 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Efficiency burner ( % ) 92 +1,5 / -0,5 92 +1,5 / -0,5 92 +1,5 / -0,5
Soot picture 0-1 0-1 0-1
Exhaust outlet temperature (°C) 160 +10 / -10 160 +10 / -10 160 +10 / -10
Exhaust temperature, cut off (°C) 270 +0 / -12 270 +0 / -12 270 +0 / -12
Fuel consump. @ dT=45 deg(kg/h) 3,4 0,0 0,1 3,6 0,0 0,1 4,0 0,0 0,1
Fuel consumption (kg/h) @ 12 °C inlet 5,2 0,0 0,0 5,2 0,0 0,0 5,7 0,0 0,0
Water volume in coil (l) 3,4 3,4 3,4
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
Gun ST ERGO 2000 ST ERGO 2000 ST ERGO 2000
UNIVERSAL PLUS UNIVERSAL PLUS TORNADO PLUS
Lance 940 940 920
DN 8x10m Quick /
Hose DN 8 x 15m DN 8 x 15m 3/8"
High pressure nozzle NT 0450 NT 0450 NT 0500
Noise level 1m Lpa( dBA) 80 +1,5 / -1,5 80 +1,5 / -1,5 75,6 +1,5 / -1,5
Noisepower LWA (dB) A 94 +1,5 / -1,5 94 +1,5 / -1,5 91 +1,5 / -1,5
Impact force N 35 39 45
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
Protection Class IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 IP X5
Max detergent flow from full internal tank (%) 4 +1 / -1 4 +1 / -1 4 +1 / -1
Max detergent flow from full internal tank (L/
min) 0,46 +0,2 / -0,2 0,49 +0,2 / -0,2 0,55 +0,2 / -0,2
Approved by SLG Chemnitz SLG Chemnitz SLG Chemnitz
Approvals CE, GS CE, GS CE, GS

Technical data B
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
Pump-Data
5,50
5,50
5,50
5,50
(bar) 125 +5 / -5 140 +5 / -5 182 +5 / -5
2,90
Flow. Qiec (l/min) % 9,40 +0,3 / -0,3 8,00 +0,2 / -0,2 13,50 +0,4 / -0,4
Flow. Qmax (l/min) 5% 10,00 +0,5 / -0,5 8,60 +0,4 / -0,4 14,40 +0,7 / -0,7
3,00
Type NA5 NA5 NA5
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 220V/1~/60Hz 230V/1~/50Hz 200V/3~/50Hz
Current consump. - hot (A) 14,3 +1,0 / -3,0 15 +1,0 / -3,0 18,9 +1,0 / -3,0
Current consump. - cold (A) 14,6 +1,0 / -3,0 15,5 +1,0 / -3,0 19,5 +1,0 / -3,0
hot 3,5 +0,5 / -0,5 3,6 +0,5 / -0,5 4,8 +0,5 / -0,5
Fuse size (A) 16 16 20
Power cord VCT
Cord type H07RN-F 4G1,5 x 6m H07RN-F 3G1,5 x 6m 4x3,5x6m
Plug type (CEE 3P+N+G / 16A) (CEE 3P+N+G / 16A)
Control PCB PCB PCB
Contactor 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW 100-C30 24V/50-60H
Eletrical test data
Motor-Data
Nominal power [kW] 2,1 2,6 4
Cos j 0,75 0,94 0,75

Technical data B
NEPTUNE 4
Gene-
ral 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
Heating Unit
@ gun (°C) 30 +0 / -3 30 +0 / -3 30 +0 / -3
(sec) 30 +5 / -5 30 +0 / -3 30 +5 / -5
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
(bar) 27 +5 / -5 61 +5 / -5 27 +5 / -5
Oil pressure ( bar ) 12 +0,5 / -0 12 +0,5 / -0 12 +0,5 / -0
1,0 60°H 1,0 60°H
Nozzle size, oil (2802717) (2802717) 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Efficiency burner ( % ) 92,5 +1,5 / -0,5 92,5 +1,5 / -0,5 92 +1,5 / -0,5
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
UNIVERSAL PLUS UNIVERSAL PLUS TORNADO PLUS
Lance 940 940 920
DN 8x10m Quick /
Hose DN 8x15m DN 8 x 15m 3/8"
Noise level 1m Lpa( dBA) 80 +1,5 / -1,5 80 +1,5 / -1,5 75,2 +1,5 / -1,5
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
min) 0,38 +0,2 / -0,2 0,32 +0,2 / -0,2 0,54 +0,2 / -0,2
Approved by ? SLG Chemnitz ?
Approvals CE CE, GS CE,

Technical data B
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
Pump-Data
5,50
5,50
5,50
5,50
(bar) 182 +5 / -5 201 +5 / -5 201 +5 / -5
2,90
Flow. Qiec (l/min) % 13,60 +0,4 / -0,4 13,70 +0,4 / -0,4 13,70 +0,4 / -0,4
Flow. Qmax (l/min) 5% 14,70 +0,7 / -0,7 14,60 +0,7 / -0,7 14,60 +0,7 / -0,7
3,00
Type NA5 NA5 NA5
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 200V/3~/60Hz 400V/3~/50Hz 400/230V/3~/50Hz
Current consump. - hot (A) 16,8 +1,0 / -3,0 12,3 +1,0 / -3,0 12,2 / 22,3 +1,0 / -3,0
Current consump. - cold (A) 17,5 +1,0 / -3,0 12,6 +1,0 / -3,0 12,5 / 23 +1,0 / -3,0
hot 4,7 +0,5 / -0,5 6,1 +0,5 / -0,5 6 / 5,8 +0,5 / -0,5
Fuse size (A) 20 16 25/16
Power cord VCT
Cord type 4x3,5x6m H07RN-F 4G1,5 x 6m H07RN-F 4G2,5 x 6m
Plug type CEE 3P+N+G / 16A
Control PCB PCB PCB
Contactor 100-C30 24V/50-60H 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW
Eletrical test data
Motor-Data
Nominal power [kW] 4 5,5 5,5
Cos j 0,75 0,75 0,75

Technical data B
NEPTUNE 4
Gene-
ral 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
Heating Unit
@ gun (°C) 30 +0 / -3 30 +2 / -3 30 +2 / -3
(sec) 30 +5 / -5 30 +5 / -5 30 +5 / -5
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
(bar) 27 +5 / -5 27 +5 / -5 27 +5 / -5
Oil pressure ( bar ) 12 +0,5 / -0 14 +0,5 / -0 14 +0,5 / -0
Nozzle size, oil 1,25 60°H 1,25 60°H 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
TORNADO PLUS TORNADO PLUS TORNADO PLUS
Lance 920 920 920
DN 8x10m Quick / DN 8x10m Quick /
Hose 3/8" DN 8x15m 3/8"
Noise level 1m Lpa( dBA) 75,2 +1,5 / -1,5 75,6 +1,5 / -1,5 75,6 +1,5 / -1,5
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
min) 0,54 +0,2 / -0,2 0,55 +0,2 / -0,2 0,55 +0,2 / -0,2
Approved by ? SLG Chemnitz SLG Chemnitz
Approvals CE, CE, GS CE, GS

Technical data B
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
Pump-Data
5,50
5,50
5,50
5,50
(bar) 201 +5 / -5 211 +5 / -5 211 +5 / -5
2,90
Flow. Qiec (l/min) % 13,70 +0,4 / -0,4 14,50 +0,4 / -0,4 14,50 +0,4 / -0,4
Flow. Qmax (l/min) 5% 14,60 +0,7 / -0,7 15,30 +0,8 / -0,8 15,30 +0,8 / -0,8
3,00
Type NA5 NA5 NA5
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 400/230V/3~/50Hz 400V/3~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 12,4 / 22,5 +1,0 / -3,0 12,5 +1,0 / -3,0 12,6 +1,0 / -3,0
Current consump. - cold (A) 12,6 / 23,2 +1,0 / -3,0 12,8 +1,0 / -3,0 12,7 +1,0 / -3,0
hot 6,2 / 6 +0,5 / -0,5 6,3 +0,5 / -0,5 6,4 +0,5 / -0,5
Fuse size (A) 25/16 16 16
Plug type CEE 3P+N+G / 16A CEE 3P+N+G / 16A
Control PCB PCB PCB
Eletrical test data
Motor-Data
Nominal power [kW] 5,5 5,5 5,5
Cos j 0,75 0,75 0,75

Technical data B
NEPTUNE 4
Gene-
ral 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
Heating Unit
@ gun (°C) 30 +2 / -3 30 +2 / -3 30 +2 / -3
(sec) 30 +5 / -5 30 +5 / -5 30 +5 / -5
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
(bar) 27 +5 / -5 27 +5 / -5 27 +5 / -5
Oil pressure ( bar ) 14 +0,5 / -0 14 +0,5 / -0 14 +0,5 / -0
Nozzle size, oil 1,25 60°H 1,25 60°H 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
TORNADO PLUS TORNADO PLUS TORNADO PLUS
Lance 920 920 920
DN 8x10m Quick /
Hose DN 8x15m 3/8" DN 8x15m
Noise level 1m Lpa( dBA) 75,6 +1,5 / -1,5 77,1 +1,5 / -1,5 77,1 +1,5 / -1,5
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
min) 0,55 +0,2 / -0,2 0,58 +0,2 / -0,2 0,58 +0,2 / -0,2
Approved by SLG Chemnitz SLG Chemnitz SLG Chemnitz
Approvals CE, GS CE, GS CE, GS

Technical data B
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
Pump-Data
5,50
5,50
5,50
5,50
(bar) 211 +5 / -5 211 +5 / -5 191 +5 / -5
2,90
Flow. Qiec (l/min) % 14,50 +0,4 / -0,4 14,50 +0,4 / -0,4 11,10 +0,3 / -0,3
Flow. Qmax (l/min) 5% 15,30 +0,8 / -0,8 15,30 +0,8 / -0,8 12,10 +0,6 / -0,6
3,00
Type NA5 NA5 NA5
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 440-220V/3~/60Hz 440-220V/3~/60Hz 230V/1~/60Hz
Current consump. - hot (A) 22,4 / 12,2 +1,0 / -3,0 22,5 / 12,4 +1,0 / -3,0 25,3 +1,0 / -3,0
Current consump. - cold (A) 23,4 / 12,6 +1,0 / -3,0 23,4 / 12,8 +1,0 / -3,0 26,8 +1,0 / -3,0
hot 6,3 / 6,5 +0,5 / -0,5 6,4 / 6,6 +0,5 / -0,5 7 +0,5 / -0,5
Fuse size (A) 24/16 24/16 30
Cord type H07RN-F 4G2,5 x 6m H07RN-F 4G2,5 x 6m SJOW AWG10/3X9.0
Plug type NEMA 6-30P
Control PCB PCB PCB
Contactor 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW CJX2D-B32
Eletrical test data
Motor-Data
Nominal power [kW] 5,5 5,5 5,5
Cos j 0,75 0,75 0,75

Technical data B
NEPTUNE 4
Gene- 4-55FA Expt 4-55FAX Expt

ral 220/440/3/60/23/1 220/440/3/60/23/1 4-36FAX USA
Description Tol. 4 4 230/1/60/30
Item no. 107146616 107146617 107146618
Heating Unit
@ gun (°C) 30 +0 / -3 30 +0 / -3 30 +0 / -3
(sec) 30 +5 / -5 30 +5 / -5 30 +5 / -5
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
(bar) 27 +5 / -5 27 +5 / -5 27 +5 / -5
Oil pressure ( bar ) 14 +0,5 / -0 14 +0,5 / -0 12 +0,5 / -0
Nozzle size, oil 1,25 60°H 1,25 60°H 1,25 60°H (61659)
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
TORNADO PLUS TORNADO PLUS UNIVERSAL PLUS
Lance 920 920 940
DN 8x10m Quick / DN 8x15m Quick /
Hose 3/8" DN 8x15m 3/8"
Noise level 1m Lpa( dBA) 77,1 +1,5 / -1,5 77,1 +1,5 / -1,5 80 +1,5 / -1,5
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
min) 0,58 +0,2 / -0,2 0,58 +0,2 / -0,2 0,44 +0,2 / -0,2
Approved by ? ? ?
Approvals CE CE CE,

Technical data B
NEPTUNE 4 FA
Gen.
Description Tol. 4-28FA Gerni 240/1/50/15 4-50FAX Gerni 400/3/50/
Item no. 107146619 107146620
Technical Data Test Result Tol. + Tol. - Test Result Tol. + Tol. -
Pump-Data
Max. inlet pressure (bar) 10 10
Max. Inlet temperature (°C) 40 40
Pressure at pump head 5,50% 99 +5 / -5 175 +10 / -10
Pressure @ Cylinder Head (bar) 5,50% 105 +6 / -6 181 +10 / -10
Pressure @ Outlet (bar) 5,50% 90 +5 / -5 171 +9 / -9
Pressure @ after Gun (bar) 5,50% 86 +5 / -5 144 +8 / -8
(bar) 130 +5 / -5 201 +5 / -5
Pressure Pmax safety valve 180 +5 / -5 250 +5 / -5
Flow. Qiec (l/min) 2,90% 9,55 +0,3 / -0,3 13,70 +0,4 / -0,4
Flow. Qmax (l/min) 5% 10,25 +0,5 / -0,5 14,60 +0,7 / -0,7
Flow. Qmin, steam (l/min) 3,00% 5,10 +0,2 / -0,2 7,00 +0,2 / -0,2
Type NA5 NA5
Piston type Ceramic Ceramic
Piston diameter (mm) 20 20
Stroke / Wobble disc angle 7,2 10,2
Oil BP Energol GR-XP Oil BP Energol GR-XP
Pump oil type 220 220
Oil volume (l) 0,95 0,95
Electronics
Elec. V/Ph/Hz 240V/1~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 14 +1,0 / -3,0 12,3 +1,0 / -3,0
Current consump. - cold (A) 15 +1,0 / -3,0 12,6 +1,0 / -3,0
Power Consumption - hot (kW) - hot 2,7 +0,5 / -0,5 6,1 +0,5 / -0,5
Fuse size (A) 15 16
Cord type H07RN-F 4G1,5 x 6m H07RN-F 4G1,5 x 6m
Plug type AS3112 (AU; 15A ) CEE 3P+N+G / 16A
Control PCB PCB
Control voltage 24 Volt-Control voltage 24 Volt-Control voltage
Contactor 100-C12KJ10 5,5kW 100-C12KJ10 5,5kW
Electrical diagram 106427175 106427170
Eletrical test data
Highvoltage (HV) test (V) 1000 Vac 1000 Vac
HV-Resistance (MΩ) ≥ 1MΩ / 500Vdc ≥ 1MΩ / 500Vdc
Cord-resistance (Ohm) 0,20 0,20
Motor-Data
Motortype 1~ Induction 3~ Induction
Rotational speed [min-1] 1450 1450
Insulation Class F Class F
Protection Class IP54 IP54
Nominal power [kW] 2,6 3 5,5
Cos j 0,89 0,75

Technical data B
NEPTUNE 4
General 4-28FA Gerni 4-50FAX Gerni

Description Tol. 240/1/50/15 400/3/50/
Item no. 107146619 107146620
Technical Data Test Result Tol. + Tol. - Test Result Tol. + Tol. -
Heating Unit
Boilerpower_input (kW) 48 66
Temperature t max, @ inlet 12° (°C) 79 +4 / -4 76 +4 / -4
Delta temp. variance at 50 °C, meassured at @ gun (° 30 +0 / -3 30 +2 / -3

Boiler on time at 50 °C set point, @ inlet 12° (sec) 30 +5 / -5 30 +5 / -5
Steam temperature t II @ outlet and v. steamnozzle (°
C) 140 +10 / -30 140 +10 / -30
Pressure P2 @ outlet v. standard nozzle (bar) 27 +5 / -5 27 +5 / -5
Fuel pump type Diesel Diesel
Oil pressure ( bar ) 12 +0,5 / -0 14 +0,5 / -0
Nozzle size, oil 1,0 60°H (2802717) 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0
Efficiency burner ( % ) 92,5 +1,5 / -0,5 92 +1,5 / -0,5
Soot picture 0-1 0-1
Exhaust outlet temperature (°C) 145 +10 / -10 160 +10 / -10
Exhaust temperature, cut off (°C) 270 +0 / -12 270 +0 / -12
Fuel consump. @ dT=45 deg(kg/h) 2,8 0,0 0,1 4,0 0,0 0,1
Fuel consumption (kg/h) @ 12 °C inlet 107,0 0,0 0,0 5,7 0,0 0,0
Water volume in coil (l) 3,4 3,4
Fuel tank (l) 15 15 15 15 15 15
Others
Gun ST ERGO 2000 ST ERGO 2000
Lance UNIVERSAL PLUS 940 TORNADO PLUS 920
Hose DN 8x10m Quick / 3/8" DN 8x15m
High pressure nozzle NT 0450 NT 0500
Noise level 1m Lpa( dBA) 80 +1,5 / -1,5 75,6 +1,5 / -1,5
Noisepower LWA (dB) A 94 +1,5 / -1,5 91 +1,5 / -1,5
Impact force N 24 45
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5
Protection Class IP X5 IP X5 IP X5 IP X5 IP X5 IP X5
Max detergent flow from full internal tank (%) 4 +1 / -1 4 +1 / -1
Max detergent flow from full internal tank (L/min) 0,38 +0,2 / -0,2 0,55 +0,2 / -0,2
Approved by SLG Chemnitz (SLG Chemnitz) ?
Approvals CE, GS CE, (GS)

Technical data B
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
Pump-Data
5,50
5,50
5,50
5,50
(bar) 201 +5 / -5 178 +5 / -5 211 +5 / -5
2,90
Flow. Qiec (l/min) % 13,90 +0,4 / -0,4 11,55 +0,3 / -0,3 14,50 +0,4 / -0,4
Flow. Qmax (l/min) 5% 14,70 +0,7 / -0,7 12,50 +0,6 / -0,6 15,30 +0,8 / -0,8
3,00
Type NA5 NA5 NA5
Oil volume (l) 0,95 0,95 0,95
Electronics
Elec. V/Ph/Hz 220/440V/3~/60Hz 400V/3~/50Hz 400V/3~/50Hz
Current consump. - hot (A) 22,3 / 12,2 +1,0 / -3,0 9,2 +1,0 / -3,0 12,6 +1,0 / -3,0
Current consump. - cold (A) 23,5 / 12,7 +1,0 / -3,0 10 +1,0 / -3,0 12,7 +1,0 / -3,0
hot 5,8 / 6 +0,5 / -0,5 4,7 +0,5 / -0,5 6,4 +0,5 / -0,5
Fuse size (A) 24/16 16 16
Plug type CEE7 / 16A Schuko CEE 3P+N+G / 16A
Control PCB PCB PCB
Eletrical test data
Motor-Data
Nominal power [kW] 5,5 4 5,5
Cos j 0,75 0,75 0,75

Technical data B
NEPTUNE 4
Gene-
ral 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
Heating Unit
@ gun (°C) 30 +0 / -3 30 +0 / -3 30 +2 / -3
(sec) 30 +5 / -5 30 +0 / -3 30 +5 / -5
steamnozzle (°C) 140 +10 / -30 140 +10 / -30 140 +10 / -30
(bar) 27 +5 / -5 27 +5 / -5 27 +5 / -5
Oil pressure ( bar ) 14 +0,5 / -0 12 +0,5 / -0 14 +0,5 / -0
Nozzle size, oil 1,25 60°H 1,25 60°H (61659) 1,25 60°H
CO2 content min ( % ) 10,5 +0,5 / -0 10,5 +0,5 / -0 10,5 +0,5 / -0
Fuel tank (l) 15 15 15 15 15 15 15 15 15
Others
TORNADO PLUS UNIVERSAL PLUS TORNADO PLUS
Lance 920 940 920
Hose DN 8x15m DN 8 x 15m DN 8x15m
Noise level 1m Lpa( dBA) 75,6 +1,5 / -1,5 80 +1,5 / -1,5 77,1 +1,5 / -1,5
Vibration ISO 5349 ( m/s² ) ≤ 2,5 ≤ 2,5 ≤ 2,5
IP
Protection Class IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 IP X5 X5
min) 0,56 +0,2 / -0,2 0,46 +0,2 / -0,2 0,58 +0,2 / -0,2
Approved by ? SLG Chemnitz SLG Chemnitz
Approvals CE CE, GS CE, GS

Construction C
Neptune 4 FA Variants.
Single phase: 4-28FAX Expt, 4-31 FAX EU, 4-37FAX USA, 4-28FA Gerni.
Three phase: 4-39FAX EU, 4-43FAX EU, 4-47FA JP, 4-50FA EU, 4-50FAX EU, 4-50FA NO,
4-55FA EU, 4-55FAX EU, 4-55FA Expt, 4-55FAX Expt, 4-55FAX Gerni, 4-50FA Expt.
X vs. Standard : Hose Reel and Hose lenght 15m on X models.
_ : These numbers refer to the theoretical total impact of spraying water calculated by the formula:
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.
The frame, cabinet, detergent tank and fuel tank is identical to previous Neptune 3 / 4 models.
Burner fan housing Fuel pump
Anti scale pump Boiler
Fuel filter Flow control
Safety valve Pressure/water

regulation
By-pass valve
Fig.C.1: Side view
Electrodes Boiler inlet
Ignition transformer Flame sensor
Boiler outlet—with Fuel nozzle

temperature sensor
Exhaust thermal
safety sensor
Fig.C.2: Top view

Construction C
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


Construction C
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 Antistone Fuel
Adjustment:
Temperature settings
Service interval settings
Detergent
Fig.C.4: Operation panel
Main switch S1 Display board A2
Fig.C.5: Panel - inside
Contactor K1
Ignition transformer T1
Exhaust temp. switch
Fig.C.6: Electrical box

Control board A1

Construction C
The electric control system is built up around the control board A1 which is divided into two sy-
stems, a 5V DC system on one side to supply the sensors B8, B4, B6, B1,B9, B7 and on the other
side it supplies the actors (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.

Detailed adjustment is described in chapter G.
Electrical diagrams can be found in chapter H.
Fuse 2 Start knob Fuse 3
B1 - B2 - MT - B4 - 24AC - B3
B7
B6
B9
B8
Data logger K1 - Y1 - 8VAC

Fig.C.7: PCB A1
Hour Display setting
Bypass time canceling

Construction C
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.
Flame sensor Electrodes Fuel nozzle Exhaust
Water outlet
Water inlet
Top plate
Air distribu-
Flame tube top part
Burner tube
Flame tube
Air inlet Fixation spacer
Outer jacket
Inner jacket
Mounting plate
Fig.C.8: Boiler
Insolation

Construction C
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. system, to stop and start the machine.

Function D
If the machine and the power supply are working correcdtly the following will happend during start
up.
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). This supplies 8 Vac and
24 Vac to the control board + microprocessor (A1) (the processor itself works on 5 Vdc). Once the 5
Vdc operating voltage of the processor is stable, it tests the following sensors: thermal release (B3),
thermal protector (MT), level of pump oil (B6). This causes all status display LEDs to illuminate for 1
s. If one of these sensors is open circuit, the motor is not powered on. The supply voltage is applied
to the main contacts (1-3-5) of the contactor (K1) for the electromotor (M1).
Once all initial requirements are satisfied, the electromotor (M1) runs and drives the HP pump for 20
s (bypass mode). If the spray device is actuated, the HP pump intakes water from the water break
tank and conveys it through the by-pass valve past the flow housing and the pressure gauge termi-
nal, through the heat exchanger to the spray device. The pressure gauge indicates the working
pressure.

Function D
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). A high-
voltage ignition spark is generated on the ignition electrodes in the burner. The burner motor (M2)
blows preheated air through the burner fan into the heat exchanger. The self-intaking fuel pump
conveys fuel under pressure to the solenoid valve (Y1).
After 1 s of preventilation the solenoid valve (Y1) opens and fuel reaches the fuel nozzle. In the bur-
ner it is atomized and ignited. The fuel pressure is applied on a line to the dosing device of the anti-
scaling valve. This opens and, depending on how it is set, conducts anti-scaling concentrate into the
water break tank. The setting of the dosing device is a function of water hardness.
The flame sensor (B7, if installed and activated) checks whether the fuel/air mixture is ignited and
allows the burner to continue running. If there is no flame 4 s after starting "Hot water" mode, the
solenoid valve closes and the burner is turned off without postventilation.
Depending on the setting of the SDR valve (selection, dosing and rinsing), the high-pressure pump
intakes detergent. Detergent alone is only drawn in by the foot valve in the maximum setting. Other-
wise the volume drawn by the pump is a water/detergent mixture.

Function D
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).
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 fuel nozzle holder (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) (if
installed and activated). 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 chimney (13).
1.) Burner fan

2.) Air distributor
3.) Fuel nozzle
4.) Heating coil
5.) Fuel pump
6.) Fuel filter
7.) Solenoid valve
8.) Fuel nozzle holder
9.) Fuel return line
10.) Ignition transformer
11.) Ignition electrodes
12.) Flame sensor (optional)
13.) Chimney
14.) Flame tube
15.) Flame funnel
16.) Insulation
17.) Water inlet
18.) Water outlet
Fig.D.2: Hot water function

Function D
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 > 270°C/ 518°F will
switch off, if the burner keeps burning without water flow through the boiler. The safety thermal
switch must be reset manually in the electrical box.
B4: Flow switch controls the motor start/stop. When pressure is higher than working pressure the
switch will open and the motor stops.
B6: Oil level-sensor stops the machine if the pump is low on oil. Activates red light on panel.
B7: Flame-sensor detects light from the flame. If the flame is not detected when it should be there,
the machine will be stopped.
B8: Level switch Anti-Stone liquid. If low, yellow light will light up.
B9: Level switch fuel (stops the fuel valve) when low on fuel and yellow light appears on the panel.
MT: Temperature switch stops the motor if the temperature in the windings is >160°C/ 320°F.
Automatic reset.
Actors:
Y1 Solenoid opens/closes the fuel for the burner.
T2: Ignition transformer is on when burner fan is running.
The machine is supplied with main power which is transformed into 8V AC to supply the micropro-
cessor and sensors and 24VAC to supply the actors (contactor, relay, solenoid valve).
To run the machine on hot water the following must be ok: on the front panel S1 and the temperatu-
re setting on hot and the spray handle open. If all the sensors are closed and ok K1 will start the mo-
tor and K2 the ignition and fan. Y1 will open and let in oil to the combustion chamber. If the flow
stops B2 will open and the 24V supply to the solenoid Y1 will be interrupted and the combustion will
stop.

Function D
C D
H
A B
E F G
J
I
Fig.D.4: Motor/pump
A: Stator. E: Suction valve.
B: Rotor. F: Pressure valve.
C: Wobble disc. G: BY-pass housing
D: Ceramic piston. H: 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” decides the volume of water which is sucked through the suction valves ”E” and
pressed out through the pressure valves ”F”.
The inlet ”I” and the outlet ”J” are connected directly to the By-pass valve ”G”.
The water volume can be adjusted by the regulation valve ”H”.

Function D
G
F
E H
D K
I J
A
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” is pressed up and the seat ”E” is closed.
G
F
E H
D K
I J
A
Fig.D.6: By-pass pressure
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”.

Function D
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”.
When the screw is tightened the cut off pressure will rise and by loosening it the pressure will
drop.
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.
G
F
E H
D K
I
A
Fig.D.8: Water reduction
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 drop depending of the size of the opening in seat ”H”.

Function D
A: Hose connection/valve seat.

D
B: Non return valves.
G C: Inlet for water from water supply.
D: Magnet piston for reed switch E

E
E: Reed switch for start of motor/pump.
I F: Water inlet from pump.

J G: Non return valve/magnet piston for H
F
H: Reed switch for start of heating
system.
H
I: Water outlet.
J: Back flow restriction.
B C
A
Fig.D.9: Flow control
Water supply connected to the machine:
Water from supply passes the non-return valves ”B” and lift up the piston ”D”.
Machine started in cold/hot water mode:
When piston ”D” is lifted up by the flow, the magnet in piston ”D” closes the reed contact NO ”E”
which gives a signal to the PC board, which starts up the motor/pump unit. The flow from the pump
lifts up piston ”G”. To secure the flow is all right, the magnet in piston ”G” closes the reed contact NC
”H” which gives the signal to the PC board. In hot water mode this signal controls the fuel solenoid
valve and the anti scale pump.
The fuel solenoid valve and the anti scale pump will activate when the PC board receives the signal
from reed contact ”H”.
Piston ”G”: When the gun is closed, piston ”G” closes the inlet of the flow control. Inside the piston
there is a retaining valve which opens when the outlet pressure in the flow control is more than10
bar higher than the inlet pressure, when the gun is released. This pressure differens will improve the
movement of piston ”G” when the gun again is activated.

Troubleshooting E
Indication lights Cause Remedy

Constant light
 The appliance is ready for operation
 When switching on, all the LEDs light up
once before the motor is switched on.
Flashing light
 Flow sensor fault  Contact Nilfisk-ALTO Service
 Water tap closed or water shortage  Cold water operation possible
 Required volume flow and pressure
 Detergent tank empty  Top up detergent tank or set detergent metering to
“OFF“
 Pressure regulation on The safety  Turn the twist grip on safety control block or Va-
control block or VarioPress-lance set to rioPress lance1) to higher water volume
low Water volume  Contact Nilfisk-ALTO Service
 Machine scaled
Not ON
 Plug not connected to the electrical  Put the plug into the electrical socket.
plug socket  Check fuse
Constant light
 Fuel shortage  Top up fuel
Cold water operation is possible
Flashing light
 Nifisk-ALTO AntiStone shortage  Top up Nilfisk-ALTO AntiStone
Constant light
 Service interval has expired  Contact Nilfisk-ALTO Service
Flashing light
 Service interval due in 20 hours  Contact Nilfisk-ALTO Service
Constant light
 Pump oil low  Top up pump oil
Flashing light (simultaneously)
 Leakage or inadmissible operating con-  After three times of short-time operation the manchi-
dition by short-time operation ne switches off. Reset: Turn main switch to position
“OFF“, then start again. Keep spray gun pressed for
longer than 3 seconds. If a leak occurs causing the
machine to start and stop briefly 3 times, then the
machine will switch off.
 Spray gun leaking  Check Spray gun
 High pressure hose, coupling or line  Replace high pressure hose, retighten screw fittings
system leaking
 Detergent tank empty  Top up detergent tank or set detergent metering to
“OFF“
 Water inlet filter dirty  Clean filter
 High-pressure pump drawing in air  Repair leaks

Troubleshooting E
Indication lights Cause Remedy

Flashing light (alternately)
 Motor overheated  Turn main switch in position “OFF“, let the machi-
ne cool down
 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
Cold water operation possible
Fault Cause Remedy

Pressure too low  High pressure nozzle worn out  Replace nozzle
 Pressure regulation set to low pressure or  Turn the twist grip on safety control block
VarioPress-lance set to low water vol- clockwise (+) or set VarioPress-lance to
ume. higher water volume.
Machine is running with  Pump has drawn in air as the detergent  Close detergent valve. Remove lance from
pulsating pressure and tank is empty. gun. Operate spray gun and let machine run
makes knocking noise until air in pump is gone and the machine is
running normally/calm again.
No detergents drawn in  Detergent tank empty  Top up detergent tank
 Dirt in detergent tank  Clean detergent tank
 Suction valve at cleaning agent inlet  Remove suction valve and clean or replace
soiled
Burner soots  Fuel contamination  Contact Alto Service
 Burner sooted or adjustment incorrect  Contact Alto Service

Troubleshooting E
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

Scale deposits in boiler tube:  The hardness of the water  Descale boiler tube.
Scale formation acts as insulation and
reduces heat transfer to the water.
The result is raised flue gastemperature
= increased flue gas loss.
Sooted boiler tube:  Air deficiency.  Check air adjustment and fan at-
Soot has the same effect as scale depo- tachment to boiler.
sits, i.e. that they are both insulating
 Bad oil/air mixture.  Check oil pressure and oil quality.
against the heat transfer to the water
Replace the oil nozzle. Adjust air
and results in increased flue gas tempe-
diffuser.
rature = increased flue gas loss.
Other symptoms are that the machine  Unfinished combustion.  Check bottom insulation, boiler top
smokes during steady operation. gasket between tube and inner
boiler jacket in top cover.
 Check burner tube.
 Unstable ignition.  Check electrodes. Adjust the air
quantity (less air).
 Leaky solenoid valve on pump  Check/replace solenoid valve Y1.
Y1.
Low oil pressure  Incorrect adjustment.  Adjust pump pressure
(see page 45).
 Filter blocked, defective pump.  Replace filter/pump. Empty and
clean tank.
Full water quantity at steam stage  Mechanical defect of by-pass  Check by-pass valve.
valve or adjustment.

Service / Repair F
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.
machine. Clean the filter and inspect for damages.
External. Back left-hand side Clean the filter.
Internal. Inside the Electrical Box. Replace if necessary.
Oil maintenance Fuel filter.
Fig.F.03: Oil extention. Fig.F.04: Fuel filter.
Check the pump oil quality and quantity. Check the fuel filter and replace if necessary.
Refill if necessary.
Change the oil at major repairs.
Type of oil, refer to part ”B”.

Service / Repair F
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.
Remove the cover by loosing the screws 
shown in the red circles. Note ! When closing the electrical box, leave
 Caution ! On 1 ~ machines capacitor might the wiring diagram inside.
still be charged !
Fig.F.07: Electrical box - Exploded view. Fig.F.08: Electrical box - Back side.
The components in the E-box are shown by Before connecting devices with voltage
numbers in the wiring diagrams chapter H. changeover: Check that the pre-selected
voltage on the machine corresponds with the
voltage of the electrical installation.
Otherwise the electrical devices of the
machine can be destroyed.

Service / Repair F
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.
Fig.F.11: By-pass - water regulation.
By reassembling of the water regulation knob,

special tool no 1211697 can be used.

Service / Repair F
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.  Inspect the thrust collar for damages
before mounting.
 Puller used in the picture is
Bahco 4521N-F.
Fig.F.14: Valve housing Fig.F.15: Valve housing
 Carefully tip out the sleeves with an  Knock carefully on the back side of the
adequate screwdriver and replace them. Be valve seat with an 8-10mm mandrel to
careful not to scratch the surface. demount and pull it out.
 Replace with new parts.

Service / Repair F
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
 The pressure valves can easily be taken  Take out the pressure valve seats with
out of the cylinder head. an adequate puller.
 Replace with new parts if necessary.  Replace with new parts if necessary.
 Puller used in the picture is Bahco

4521N-00

Service / Repair F
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.
 Puller used in the picture is Bahco
4521N-F.
Oil seal and piston
Fig.F.22: Valve Kit 3~ - Exploded View Fig.F.23: Pistons
 To make replacement easier moisten the  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.

Service / Repair F
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-
der.
Fig.F.25: Damaged header ring

Service / Repair F
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.
Fig.F.28: Wobble disc Fig.F.29: Wobble disc removal
 The center bolt is fixing the wobble disc  Demount the wobble disc screwing a
to the motor shaft and ensure the rotor to  16mm 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.

Service / Repair F
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
& Fig.33 pos. A & B
B
A
Fig.F.32: Bearing track Fig.F.33: Bearing track
 The curved edge (A) of the bearing tracks  The sharpe edge (B) of the bearing track
must be mounted against the D-bearing must be mounted against the bearings
cover and the wobble disc.

Service / Repair F
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.
replace the complete D-bearing cover.  Mount the oil sleeve by using an
adequate box spanner and a fiber
hammer.
Electrical motor
Fig.F.36: Electrical Motor Fig.F.37: fan
 Overview of the motor parts.  The fan can be demounted by taking off
the lock ring and carefully push the fan
with a screwdriver.

Service / Repair F
Fuel tank. Heating system.
1.
2.
3.
4.
2
5.
6.
3
Fig.F.38: Fuel tank - Overview. Fig.F.49. Boiler top
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. Ignition electrodes 6. Air distributer.
4mm
5mm
5mm
Fig.F.40: Fuel nozzle. Fig.F.41: Fuel nozzle.

Service / Repair F
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.
Burner Unit.
Fuel solenoid
Fuel pump
Burner motor
Burner housing
Fuel filter
Fan
Fan cover
Fig.F.44: Burner unit.

Service / Repair F
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. Keep the coil close to the ma-
the nuts. Dismount the 4 nuts chine.
"Arrows"and hook up the crane and lift out the
coil.
When landing on the floor press over to the
side or protect the machine by a piece of card-
board.
Fig.F.47: Dismounting coil Fig.F.48: Inspection of coil
Check the flame tube A and B. It is important Clean up deposits and change the isolation if
that they are solid and whole. needed.

Adjustment / Test G
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

Adjustment / Test G
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 Turn pressure bolt (B . Fig. G12) 1 to 2 turns
chapter B. out, to ensure that a too high cut off pressure
will not damage the by-pass valve.
Close the safety valve completely.
Adjust the test tap (A. Fig G.09 & G.10) and
the pressure bolt (B) so it couples 20-30 bars
higher than working pressure, when the pres-
sure gun is closed— CUT OFF PRESSURE.
After the cut off pressure is reached the ma-
chine runs in by-pass untill the pressure gun is
opened.

Adjustment / Test G
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 > 60 bar higher than working pressure, couples out (go into bypass). Then you turn
the by-pass valve can be damaged due to fast the adjusting “screw” a ½ turn back
and hard movements during the change from (Clockwise) and lock it with the counter nut.
working pressure to by-pass pressure. Open and close the pressure gun a couple of
times to check the adjustment.
Finalize the adjustment with locking glue/paint
on both the bolt and the safety valve.

Adjustment / Test G
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. Let the machine run in "Hot water" mode for at least two minutes so that it reaches operating tem-
perature 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 mea-
sures 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.
Fig.G.15: Fuel pressure setting. Fig.G.16: Air flap.
Mount pressure gauge on the fuel pump. The air flap on the side of the burner fan is
Adjust 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 in-
take, turning counterclockwise reduces it.

Adjustment / Test G
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". Otherwise, open the air can be done with conventional meters or, as in
flap (Fig.G.07) a little and repeat the measure- Fig. G.08, with an electronic meter like the
ment. Repeat the procedure until the specified TESTO 327 (4), which measures and displays
value is obtained. 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.

Adjustment / Test G
Electronic settings.
1) BR1
2) BR2
3) X5
4) Fuel LED
5) Anti Scale LED
6) Service LED
7) Pump oil LED
8) Operation LED
9) 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
BR2 (2): this can be used to activate the optional flame probe.
- Jumper on 1/2: flame probe inactive
- Jumper on 2/3: flame probe active
X5 (3): the data logger is connected here for readout of operating data. X5 is also im-
portant for setting the service interval.
Service interval settings:

Switch off the machine with S1. Place a wire jumper (9) between pins 3 and 5 on X5.
Switch on the machine ("Cold water" mode). By temperature setting it is now possible
to set a new service interval, read from the status display LEDs (4-8): beginning with
the "Fuel" LED (4), each LED stands for 100 h, producing a setting range of 100 to 500
h in 100 h increments. If the setting is not altered for 3 s, the value is assumed, indica-
ted by flashing of the set LEDs. The machine must then be switched off by S1, and the
wire jumper removed from X5. The default ex works is 200 h.

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

Wiring diagrams H

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NEPTUNE 4 FA

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See ”Technical Service Bulletin” (TSB) sheets—

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 2

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 3

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For your own safety Observe valid safety regulations

Before using the cleaner, always

 Touch the earth conductor before repairing the cleaner

 Wear wrist band if necassary.

 Use a conductive floor covering or a conductive table cover.

 Never touch the printed circuit board or electronic components

 Transport electronic components in conductive packaging

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 4

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Gen. 4-43FAX EU 4-50FA EU

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 5

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 6

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Gen. 4-28FAX Expt 4-25FAX EU

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 7

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 8

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Gen. 4-50FAX EU 4-50FA NO

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 9

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 10

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Gen. 4-50FAX NO 4-55FA EU 4-55FAX EU

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 11

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 12

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Gen. 4-55FA Expt 4-55FAX Expt 4-36FAX USA

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 13

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Gene- 4-55FA Expt 4-55FAX Expt

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 14

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 15

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General 4-28FA Gerni 4-50FAX Gerni

Delta temp. variance at 50 °C, meassured at @ gun (° 30 +0 / -3 30 +2 / -3

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 16

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Gen. 4-50FA Expt 4-55FAX EU

NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 17

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NEPTUNE 4 FA_EN_Ver.2.0_ 22/11 18

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Burner fan housing Fuel pump

Anti scale pump Boiler

Fuel filter Flow control

Safety valve Pressure/water