NEPTUNE 8. Supplement to Service Manual NEPTUNE 5 / 7

NEPTUNE 8 Supplement to Service Manual NEPTUNE 5 / 7

A. Safety instructions B. Technical data C. Construction D. Function E. Troubleshooting F. Maintenance / repair G. Adjustments H. Wiring diagrams I. Special tools / spare parts

Index Preface A. Safety Instructions B. Technical Data 1. Neptune 8-103 *EU* C. Construction D. Function 1. Soft start E. Troubleshooting... 1... 2... 3... 4... 7... 8 Index F. Maintenance / Repair 1. Maintenance... 9 2. HP pump (N8) 2.1. Survey... 10 2.2. Collar set... 11 2.3. Connecting rod... 11 2.4. Torque values... 12 3. Electrical system 3.1. Soft start... 13 3.2. Motor supply line... 13 G. Adjustments H. Wiring Diagrams 1. Wiring diagram parts list 2. 3~ star (71342) I. Special Tools / Spare Parts Notes... 14... 15... 16... 17... 18 Neptune 8_EN_Ver.1.0_01/05

Preface Preface There are only minor differences between the NEPTUNE 8 hot-water high-pressure cleaner and the NEPTUNE 5 / 7 line of products. This service manual therefore only describes the differing components and is intended as a supplement to the NEPTUNE 5 / 7 service manual. Repair work requires a suitable testing workplace with the necessary power supply. If operating errors are evident, refer the customer to the user manual. A fault in the cleaner can have a number of causes. Refer to Chapter E for troubleshooting. Also refer to the illustrated spare parts list (part number: 301002064) for your repairs. This shows you the location of the individual parts and the sequence in which they are assembled. Read the "Service / Technical Information" sheets. They include information on technical modifications that have been made after this service manual was printed. "Service / Technical Information" sheets are also valid as a supplement to the spare parts list until publication of a new edition. Service manuals and Service / Technical Information sheets should be available at the site where repairs are carried out. It is not permitted to give them to third parties. Use originalnilfisk spare parts only! Neptune 8_EN_Ver.1.0_01/05 1/21

Safety instructions A Safety instructions For your own safety Observe national safety directives and regulations for the electrical engineering trade, in particular: IEC 60335-2-69 EN 60335-2-69 Repairs should only be made by someone who has received proper instructions for the job or who is a qualified electrician. Before starting the equipment, be sure to read the accompanying operator manual, and keep it close as ready reference. The equipment should only be used by persons who have been instructed in its use and are authorized to do so. ESD (electrostatic discharge) Observe the following ESD precautions before any repair of or near electronic parts: Touch the protective conductor to discharge your own body. Possibly wear an anti-static wrist strap. Use a conducting floor or tabletop. Never touch a circuit board or electronic components always hold it by the plastic or insulation. Transport electronic parts in conductive packaging (e.g. special ESD packages). Neptune 8_EN_Ver.1.0_01/05 2/21

Technical data NEPTUNE 8 Neptune 8-103 *EU* B 1. NEPTUNE 8-103 Technical machinedata Motor Pump Heat exchanger Dimensions and weight Machine protection category IP X5 Current consumption A 22,4 Voltage V 400-415 Frequency Hz 50 Connected load kw 12 Sound pressure db (A) 80,2 HP nozzle 1200 Pressure P1 / P1 max. bar 180 / 250 Pressure P2 / P2 max. bar 25 / 32 M ax. recoil force N 103 W ater throughput (max.) l/h 2000 W ater throughput (EN 60335-2-79) l/h 1950 W ater intake pressure (m ax.) bar 10 W ater intake temperature (max.) C 40 Voltage V 230-400 Frequency Hz 50 Connected load kw 11 Motor insulation CL. F Ingress protection IP 44 RPM U/min 1450 Type N8 30.20 Plunger ceramic Plunger diameter mm 22 Plunger stroke mm 19,8 Pump oil SAE 15 W 40 Amount of oil ml 2150 Fuel pressure bar 12,5 Fuel consumption dt = 45 K kg/h 6,0 Exhaust temperature C 185 CO 2 content (min.) % 10,5 (+0,8) Soot rating 0-1 Efficiency % > 92 W ater content (coil) l 6,12 Heating power kw 115 Length mm 1190 W idth mm 702 Height mm 1020 W eight kg 228 Miscellaneous Table B.1: Neptune 8-103 High-pressure hose m 10 Electrical lead m 5 Fuel tank l 35 Detergent tank l A: 15 / B: 10 Neptune 8_EN_Ver.1.0_01/05 3/21

Construction C 5 Construction The outer design of the Neptune 8 hot-water highpressure cleaner is completely identical to the Neptune 7 line of products. As far as sensors, control, functionality and electronics are concerned, there are also no differences to the Neptune 5 / 7 series. For further details about the construction of the machine, refer to the Neptune 5 / 7 Service Manual. Fig. C.1: Neptune 8-103 2 3 Fig. C.2: Neptune 8-103 with cover hood and side panel removed 1 4 Due to the higher performance specifications of the Neptune 8, the main differences to the Neptune 5 / 7 series are found in a modified, larger dimensioned motor/pump unit. In detail, this results in the following constructional differences: soft start (1) for the pump motor pump motor (2) without attachment plug pumping set (3) with modified water and detergent intake In addition to the basic design changes from the Neptune 5 / 7 series listed above, there are further less evident constructional differences: control safety block (4) float valve The Neptune 8 machine is available in one version only: Neptune 8-103: 3~ This machine is equipped with a storage tray (5) for accessories, tools, etc. as standard. Upgrading with a hose reel or hose and cable reels is possible. Fig. C.1 & C.2: 1.) Soft start 2.) Pump motor 3.) Pumping set (N8) 4.) Control safety block 5.) Storage tray Neptune 8_EN_Ver.1.0_01/05 4/21

Construction Soft start of the pump motor C Construction 4 3 2 The soft start electronic circuitry is located in a separate housing (1) mounted with a bracket (2) to the central tube (3) of the machine. The connecting line (4) is led from the housing (1) directly into the rear of the electric box of the machine. For further details, refer to Chapter F.3.1. 1 Fig. C.3: Soft start housing mounted to central tube Pump motor without attachment plug 6 Due to the higher current consumption compared to the Neptune 5 / 7 line of products and incompatibility of the motor (5) to the existing cold-water series, the motor line (6) is not provided with an attachment plug. The motor line (6) is led directly into the rear of the electric box of the machine. The star connection is implemented in the motor (5). 5 For further details, refer to Chapter F.3.2. Fig. C.4: Pump motor without attachment plug Pumping set (N8) with modified water and detergent intake 10 10 7 Fig. C.5: Pumping set (N8) 8 9 The N8 pump (7) is basically constructed similar to the NP5 pump, only being dimensioned larger. The weight of the pump (7) is therefore supported by a support foot (8). Detergent is taken in directly behind the outlet of the water break tank (Fig. C.5; detail) and not from the valve block (9). The water feed hose (10) to the pump (7) is connected to the valve block (8) at the motor side. For further details see Chapter F.2. Fig. C.3 - C.5: 1.) Soft start housing 2.) Soft start housing bracket 3.) Central tube 4.) Connecting line 5.) Motor 6.) Motor line 7.) N8 pump 8.) Support foot 9.) Valve block 10.) Water feed hose Neptune 8_EN_Ver.1.0_01/05 5/21

Construction Control safety block C Construction 1 2 The following modifications were made to the control safety block compared to the Neptune 5 / 7 series: The pressure hose (1) to the heat exchanger was changed to DN10. Never use the pressure hose of the Neptune 7 machine. The housing (2) for the magnetic contact piston of the flow sensor was lengthened. The magnetic contact piston was replaced by a larger one (diameter: 13 mm). For further details, refer to the Neptune 8 list of spare parts. Fig. C.6: Control safety block of Neptune 8 Float valve 5 3 6 4 Compared to the Neptune 5 / 7 series, a float valve (3) with larger nominal width (Neptune 5 / 7: DN10; Neptune 8: DN17) is used. Therefore, the water inlet filter (4), float (5) and membrane (6) are also different. For further details, refer to the Neptune 8 list of spare parts. Fig. C.7: Water break tank with new float valve Although the Neptune 8 and the Neptune 5 / 7 series are largely identical, be sure to use the Neptune 8 list of spare parts when ordering parts for this machine! Fig. C.6 & C.7: 1.) Pressure hose 2.) Housing 3.) Float valve 4.) Water inlet filter 5.) Float 6.) Membrane Neptune 8_EN_Ver.1.0_01/05 6/21

1 2 Nilfisk Function D 1. Soft start There are no functional differences between the Neptune 5 / 7 series and the Neptune 8. However, due to the higher capacity of its motor/pump unit, the Neptune 8 must be started up using a so-called soft start function. B1 B4 P A1 X5-13 X5-15 X5-5 Datalogger X2 5V DC + ~ F1 X4-21 X4-23 X4-17 X4-19 X4-15 B3 T1 8V AC 12 13 11 7 24V AC 14 4 S1 400V AC 12 1a 2a PE L1 L2 L3 B6 X5-7 X5-9 F2 X4-13 X4-9 MT X4-11 X5-11 B7 B8 B9 S1 4 4a X6-9 X6-11 X5-1 X5-3 X6-1 X6-3 X6-6 X6-7 X1a X1b µp Remote X7 X3-1 X3-9 X3-5 X4-5 X4-7 X4-1 X4-3 X3-7 X3-3 X3-11 Q B2 Y1 K1 A1 A2 K2 A1 A2 13 5 24 6 A3 L1 L2 T1 T2 X11 X12 F11 13 14 11 M2 M 1~ X13 14, 24 T2 A2 Temp. Operation Fuel Pump Oil Service Anti Stone Display U1 V1 W1 M1 M 3~ U2 V2 W2 Fig. D.1: Wiring diagram of Neptune 8 The soft start function provides current limitation during the start-up phase (1 second). This is realised by phase control to 2 phases (Fig. D.1.; red border). A potentiometer (1) installed on the soft start board may be used to set the starting torque of the machine. The torque is preset in the factory and normally needs not be changed. For further details about the functionality, refer to the Neptune 5 / 7 Service Manual. 1 Fig. D.2: Neptune 8 soft start board Fig. D1 & D2: 1.) Potentiometer Neptune 8_EN_Ver1.0_01/05 7/21

Troubleshooting E Troubleshooting The microprocessor control of the Neptune 8 is identical to that of the Neptune 5 / 7 series. The machine shows the same error codes on its display, which may to be used to find out the cause of a possible malfunction. Other troubleshooting procedures are also identical. For detailed troubleshooting information, refer to the Neptune 5 / 7 Service Manual. Further useful leads and information for troubleshooting the machine can be found in the respective Service / Technical Information sheets (STIs) for the Neptune 5 / 7 series. Neptune 8_EN_Ver.1.0_01/05 8/21

Maintenance / repair F 1. Maintenance Maintenance plan Maintenance task Cleaning water filter Cleaning oil filter Checking pump oil quality Changing pump oil Emptying fuel tank Flame sensor Weekly After the first 50 operating hours Every 6 months or 500 operating hours As required Table F.1: Maintenance plan All maintenance tasks in accordance with the maintenance plan for the Neptune 8 are the same as required for the Neptune 5 / 7 series. The only difference is the location of the pump inlet filter: 1. Unscrew the union nut (1) at the water inlet coupling. 2. Remove the filter (2) using pliers or another suitable tool and clean it. If necessary replace the filter (2). 1 2 1 Fig. F.1: Water inlet at HP pump In addition to the Neptune 5 / 7 Service Manual, also see the corresponding User Manual (p/n 301002099) for further information on maintenance and maintenance plan. Fig. F.1: 1.) Union nut 2.) Filter Neptune 8_EN_Ver1.0_01/05 9/21

1. Survey Maintenance / repair F 2. HP pump (N8) 4 6 3 1 5 2 4 Fig. F.2: HP pump of Neptune 8 (exploded view) 7 4 2 Fig. F.3: HP pump of Neptune 8 (sectional model) The HP pump used is a bidirectional three-piston straight-type pump with ceramic pistons (1). Its function and design are almost identical to the NP5 pump. The pump housing (2) is flange-mounted axially onto the electric motor. The rotor shaft projects from the motor and is used as a drive shaft (3) for the HP pump. The crankshaft (3) is seated in two identical roller bearings (4). (Note: Different roller bearings are used in the NP5 HP pump.) They ensure smooth operation and long service life. Multigrade oil is used for lubrication of the HP pump. (Note: About 2150 ml are required for the NP8 pump vs. approx. 1000 ml for the NP5 pump.) Differences also exist in the design of the collar sets (5) and pump connecting rods (6). Fig. F.2 & F.3: 1.) Ceramic piston (sleeve) 2.) Pump housing Neptune 8_EN_Ver1.0_01/05 3.) Crankshaft 4.) Roller bearing 5.) Collar set 6.) Pump connecting rod 10/21

Maintenance / repair F 2. Thrust collar set 2. HP pump (N8) In contrast to the NP5 pump, the collar set of the N8 pump is composed of a two-piece thrust collar package. High-pressure package: 1.) Support ring 2.) High-pressure sleeve 3.) High-pressure thrust collar 1 2 3 4 5 6 7 8 Low-pressure package: 4.) Support ring (not shown in lower part of Fig. F.4) 5.) Low-pressure sleeve 6.) Low-pressure thrust collar 7.) O-ring Fig. F.4: Thrust collar set of N8 pump For the fitting positions, refer to the illustrations in Fig. F.4. Caution: When fitting or removing the thrust collar sets be sure not to scratch the thrust collar. Liberally grease the sleeves, their seats and O- rings. Do not re-use a sleeve once it has been removed. 3. Connecting rods 10 9 A A 9 A A 9 A A The three connecting rods (9) in the N8 HP pump are designed in two parts. Before removing the crankshaft (10) unscrew the hexagon screws (arrows A) and remove them together with the loose part of the pump connecting rod (9). Should the parts be re-used, mark the order of assembly and re-install them accordingly. When mounting the connecting rods (9) be sure to lubricate the bearing faces of the rods (9) and not to jam the rods. Tighten the fastening screws (arrows A) alternately and evenly. Fig. F.5: Pump housing opened (view from the rear) Fig. F.4 & F.5: 1.) Support ring 2.) HP sleeve 3.) HP thrust collar Neptune 8_EN_Ver1.0_01/05 4.) Support ring 5.) LP sleeve 6.) LP thrust collar 7.) O-ring 8.) Oil seal (piston) 9.) Pump connecting rod 10.) Crankshaft 11/21

4. Torque values Maintenance / repair F 2. HP pump (N8) D 2 F C G 1 B E D A E Fig. F.6: HP pump of Neptune 8 (exploded view) Torque values Valve block screws: 50 Nm (arrow A) Piston nut: 12 Nm (arrow B) Housing cover screws: 10 Nm (arrow C) Bearing cover screws: 24 Nm (arrow D) Valve plugs: 67 Nm (arrow E) Connecting rod bolts: 10 Nm (arrow F) Crankshaft (w/o oil filling): 0.2-0.8 Nm (arrow G) Adjusting washers (2) with four different thickness (0.05 / 0.10 / 0.19 / 0.25) are available for adjustment of the torque at the crankshaft (1). On account of the similar designs of the N8 and NP5 pumps, information on assembly of the components can also be taken from the Poseidon 5 or Maxxi 4 Service Manual, in addition to the details available in the Neptune 5 / 7 Service Manual. Fig. F.6: 1.) Crankshaft 2.) Adjusting washer Neptune 8_EN_Ver1.0_01/05 12/21

1. Soft start Maintenance / repair F 3. Electric system 5 4 3 A 2 1 Fig. F.7: Soft start housing mounted to central tube The soft start circuitry is located in a housing (1) mounted on a bracket (2) clamped to the central tube (3) of the machine. When working on the soft start circuitry - in particular when the housing cover (4) is opened - be sure to first turn off the machine and pull out the mains plug. Before removing the complete soft start box including its bracket (2), turn off and unplug the machine. Then, as required, disconnect the connecting line (5) of the electronic circuitry (either directly at the electric box or at the control circuitry). Then loosen the retaining screw (arrow A) and lift out the complete unit along the central tube (3). For further details about assembly, refer to the corresponding spare parts list. 2. Motor supply line 7 6 The motor line (6) is connected without an attachment plug to the motor (7). Therefore, the motor (7) must be disconnected at the electric box for removal. First turn off the machine and disconnect it from the mains supply (unplug). If the complete motor/pump assembly has to be pulled out for repair or maintenance work, disconnecting the motor line (6) is not necessary because the line has sufficient length to allow this. However, before pulling out the motor/pump assembly ensure that the motor line (6) is freely movable. For further details about assembly, refer to the corresponding spare parts list. Fig. F.8: Pump motor without attachment plug Fig. F.7 & F.8: 1.) Housing 2.) Bracket 3.) Central tube 4.) Housing cover 5.) Connecting line 6.) Motor supply line 7.) Motor Neptune 8_EN_Ver1.0_01/05 13/21

Electronic circuitry: Adjustments Adjustments see Neptune 5 / 7 Service Manual. G Adjustments Control safety block: Adjustment procedure see Neptune 5 / 7 Service Manual or STI 390. Heat exchanger system: Adjustment procedure see Neptune 5/7 Service Manual or STI MPW- 005. Settings: NEPTUNE 8-103 CO 2 content % 10.5 (+ 0.8) Fuel pressure bar 12,5 Soot rating 0-1 Flow control: AntiStone device: Soft start: Adjustment procedure see Neptune 5 / 7 Service Manual. Parameters for adjustment see Neptune 5 / 7 Service Manual. (Neptune 8 is set similar to Neptune 7.) The starting torque of the electric motor has been set correctly in the factory. Further adjustment is generally not required. Neptune 8_EN_Ver1.0_01/05 14/21

Wiring diagrams H Note: The components listed in Table H.1 relate to the following Neptune 8 wiring diagram. 1. Wiring diagram parts list Code Component designation A1 Processor Board A2 Display Board A3 Softstarter B1 Temp. Sensor B2 Flow switch B3 Safety thermal switch B4 Micro switch B6 Level switch pump oil B7 Light sensor B8 Level switch anti stone B9 Level switch fuel F1/F2/F11 Fuse K1 Contactor K2 Relay M1 Motor 3~ M2 Burner motor MT Temp. switch motor S1 Switch on/off T1 Control transformer T2 Ignition transformer X1a/b Connector display board X2 Pin contacts 5pol. data logger X3-X6 Terminal strip X7 Connector remote control X11/12/13 Terminal Y1 Magnet valve Table H.1: Wiring diagrams parts list for Neptune 8 Neptune 8_EN_Ver.1.0_01/05 15/21

Wiring diagrams H 2. Three-phase star (71342) 1a 2a 12 1 2 B1 B4 B6 B7 B8 B9 S1 A1 Datalogger X2 5V DC + ~ F1 X5-13 X5-15 X5-5 P X5-7 X5-9 X5-11 X6-9 µp X6-11 X5-1 X5-3 X6-1 X6-3 4 X6-6 4a X6-7 X1a X1b Remote X7 A2 Temp. Display Operation Fuel Pump Oil Service Anti Stone Fig. H.1: Wiring diagram three-phase star F2 X4-21 X4-23 X4-17 X4-19 X4-15 X4-13 X4-9 X4-11 X3-1 X3-9 X3-5 X4-5 X4-7 X4-1 X4-3 X3-7 X3-3 X3-11 Q B2 Y1 8V AC 24V AC B3 K1 T1 11 7 12 13 14 MT A1 A2 S1 400V AC 4 K2 A1 A2 PE L1 L2 L3 13 5 24 6 A3 L1 L2 T1 T2 X11 X12 U1 M1 V1 W1 M 3~ U2 V2 W2 F11 M2 X13 M 1~ 13 14 11 14, 24 T2 Neptune 8_EN_Ver.1.0_01/05 16/21

Special tools / spare parts I Special tools / spare parts / service accessories Part number Description Remarks Special tools (1) 17237 Soot pump with filter paper and soot rating scale 17238 Filter paper 17239 Soot rating scale 17240 CO 2 meter with refill fluid 17241 CO 2 metering fluid 17242 Gas thermometer (pointer) 17243 Test case (empty) 17246 Fuel pressure meter 40471 Gas thermometer (LCD) 40472 Exhaust loss calculator 63138 Test bolt 301000383 Datalogger 301001078 Service crane 301001089 Chimney adapter 301002067 TESTO exhaust air probe see also STI MPW/SPW-011 301001875 TESTO central unit see also STI MPW/SPW-011 301001090 Crane eye Spare parts / repair kits (2) 301000911 Safety valve 301002071 Repair kit CSB 310001130 Attachment set: hose & cable drum 301001131 Attachment set: hose drum 301002050 Kitpiston22mm 301002053 Kit piston sealing 22 mm 301002051 Kit oil sealing 301002055 Kit support ring 22 mm 301002039 Kit valve (x6) 3812385 Fuse 5 x 20; 6,3A/250V F11 24499 Fuse 5 x 20; 315 m F1 3812625 Fuse 5 x 20; 2,0A/250V F2 Service accessories (3) 41455 Grease (-15 to +130 C), 50 g tube; foodsafe 33397 Loctite 242, 50 ml bottle 33667 Silicone grease, 100 g tube Sealing varnish, commercial standard Silicone spray, commercial standard Copper paste, commercial standard Table I.1: Special tools, spare parts and service accessories Further details concerning special tools, spare parts and service accessories can be found in the Neptune 3 and Neptune 5 / 7 Service Manuals as well as in diverse STI s. Neptune 8_EN_Ver.1.0_01/05 17/21

Notes Notes Neptune 8_EN_Ver.1.0_01/05 18/21

Notes Notes Neptune 8_EN_Ver.1.0_01/05 19/21

Notes Notes Neptune 8_EN_Ver.1.0_01/05 20/21

Notes Notes Neptune 8_EN_Ver.1.0_01/05 21/21