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Service Manual

NEPTUNE PE/DE

NEPTUNE PE-DE_en_Ver.1.0_October 2010

Jetwash Direct ltd

Summary of Contents for NEPTUNE 5-46 PE

Page 1: ...Service Manual NEPTUNE PE DE NEPTUNE PE DE_en_Ver 1 0_October 2010 Jetwash Direct ltd...

Page 2: ...A B C D E F G H Wiring diagrams 72 92 Adjustment Test 63 71 Service Repair 42 62 Troubleshooting 38 41 Function 18 37 Construction 10 17 Technical data 6 9 Safety instructions 5 Jetwash Direct ltd...

Page 3: ...tion Electrical 18 Funktion PCB 24 Pumps 28 By pass valves Unloader 31 Flow Switch 35 Heat Exchanger 36 E Troubleshooting Table 38 F Service Repair NA5 Pump 42 C3 Pump 48 NP5 Pump 54 Heat Exchanger 59...

Page 4: ...n have several causes as described in the section on trouble shooting Refer to the illustrated spare parts lists during repairs They show the assembly posi tion and the sequence in which the individua...

Page 5: ...tions and keep them readily available The high pressure cleaner should only be used by author ized persons who have been instructed in its use Although extremely easy to operate children should not be...

Page 6: ...Suction capacity feeded meter 3 3 Pump inlet temperature C 35 40 35 40 Fuel pressure bar 12 10 Fuel consumption dt 45 C kg h 3 9 3 9 CO2 content min 10 5 10 5 Soot rating 0 0 Efficiency 92 92 Onboard...

Page 7: ...5 Suction capacity feeded meter 3 5 Pump inlet temperature C 35 40 35 40 Fuel pressure bar 11 12 Fuel consumption dt 45 C kg h 4 6 5 75 CO2 content min 10 5 10 5 Soot rating 0 0 1 Efficiency 92 92 Onb...

Page 8: ...pacity feeded meter 3 5 Pump inlet temperature C 35 40 35 40 Fuel pressure bar 10 12 Fuel consumption dt 45 C kg h 3 9 4 85 CO2 content min 10 5 10 5 Soot rating 0 0 1 Efficiency 92 92 Onboard fuel ta...

Page 9: ...l min 21 5 Suction capacity feeded meter 5 Pump inlet temperature C 35 40 Fuel pressure bar 12 Fuel consumption dt 45 C kg h 5 CO2 content min 10 5 Soot rating 0 1 Efficiency 92 Onboard fuel tank Lit...

Page 10: ...l pump access through the square hole on the right side of the fuel tank Honda motor 230V Generator NA5 pump Water regulation pump By Pass valve Temperature sensor pump Oil container w oil level switc...

Page 11: ...UNE 7 61PE front side The NEPTUNE 7 61PE is designed with a C3 high pressure pump a Honda GX390 motor with 13 HP control system same as on the NEPTUNE 3 and a NEPTUNE 5 boiler Fuel pump access through...

Page 12: ...PE DE_en_Ver 1 0_October 2010 12 Overview NEPTUNE 7 61PE NEPTUNE 7 61PE boiler top IN OUT Flame sensor Temperature sensor boiler exhaust Fuel nozzle Electrodes Temperature Sensor Flow switch Flow swi...

Page 13: ...Construction C NEPTUNE PE DE_en_Ver 1 0_October 2010 13 NEPTUNE 7 61PE backside Overview NEPTUNE 7 61PE Generator 230V Top cover Charging relay Jetwash Direct ltd...

Page 14: ...or NP5 pump Temperature sensor pump Oil glass w level switch Water inlet Unloa der Safety valve This safety valve is used only on 5 85PE and 5 51DE becasue the unloader does not have a safety valve Ge...

Page 15: ...s through the square hole on the right side of the fuel tank Battery 12V Generator 230V Yanmar motor Temperature sensor exhaust Temperature sensor water outlet Flow switch 1 and 2 Safety valve only on...

Page 16: ...ump access through the square hole on the right side of the fuel tank Rugerinni motor Oil container w level sensor Gera box between motor and pump C3 pump By pass valve W water regulator Temperature s...

Page 17: ...7 boiler Fuel pump access through the square hole on the right side of the fuel tank Temperature sensor pump By pass valve w water regu lator C3 pump Mitsubishi motor Oil container w level sensor Tem...

Page 18: ...let go the key the key moves back to the ON position When the key is turned to the start position the start relay 13 is pulled and the start motor is turn ing the motor In the ON position the battery...

Page 19: ...the pump or the motor oil switch is closing failure is respectively in put 9 and input 8 connected to ground which causes the LED to light and at the same time output 15 is connected to ground If the...

Page 20: ...rmostat E on the high pressure pump the motor oil switch D and the oil level switch in the high pressure pump If the thermostat E on the pump is closing failure is input 8 connected to ground which ca...

Page 21: ...switch opens and there is no connection to ground anymore When no con nection to ground there is no ground on output 15 which means the motor runs If output 15 is connected to ground 5 sec after the k...

Page 22: ...Y2 red wire is no longer pulled but the holding coil Y2 white wire is kept hold through the contactor K3 If there is a failure on B5 oil level switch pump oil B10 Motor oil switch B11 thermo switch m...

Page 23: ...is a failure on B5 oil level switch pump oil B10 motor oil switch or B12 thermo switch high pressure pump is output 15 on A2 connected to ground At the same time input F on the Honda motor is connect...

Page 24: ...es is the same as used in NEPTUNE 3 The only difference is the following bridges which are mounted on the circuit board in the NEPTUNE PE DE machines X4 5 to X5 6 oil level switch high pressure pump O...

Page 25: ...ol circuit board goes into failure mode If the S1 main switch is turned to hot water mode and the spay gun is open and desired tempera ture set at S1 B1 temperature sensor is measuring lower temperatu...

Page 26: ...urner to burn If the flame sensor don t see the flame after 4 sec when S1 is in hot water mode the fuel solenoid valve will close and the burner will be stopped If the display is flashing in the LED s...

Page 27: ...D s Pos 4 Fuse Self resetting Pico fuse Pos 5 Fuse Pos 6 Fuse Control Circuit Board A1 On the above picture is the correct setting of the circuit board Arrow 1 Setting is WITHOUT JUMPER By pass time a...

Page 28: ...alve Pressure valve OIL Cam shaft Shaft The three pistons are driven by the motor via a belt drive The cam shaft transforms the rotation power into the pistons reciprocating movements The movement and...

Page 29: ...he NEPTUNE 5 46PE and 5 54PE The NA5 pump is connected to the Honda motor with a direct drive By pass valve function is described later in this service manual Honda motor and D bearing cover Pistons c...

Page 30: ...here the water is running through in order to create a pressure drop which make sure the valve cone is closed during opera tion When water flow is interrupted the pressure rises until the safety valve...

Page 31: ...er pressure the by pass piston B is pressed up and the seat E is closed Working pressure A B I C D J E F G H K Machine is started and the gun is closed By pass pressure When the gun J closes the press...

Page 32: ...fall 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...

Page 33: ...of the piston This will keep the valve cone D closed against its seat E because the piston C is fixed to the valve cone By Pass When the water consumption stops spray handle is released closed the pre...

Page 34: ...the pump is running the unloader piston 2 is pressed down it its seat 1 and all the water volume is going through the gun and out to the high pressure nozzle When the gun is released no water flow ou...

Page 35: ...ing and the reed switch is making contact and closing the circuit When the spray handle is released and the water flow stops the flow switch pistons will move away from the reed switches and the will...

Page 36: ...filter 6 The fuel is conducted by the solenoid valve 7 to the nozzle stock 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 transfo...

Page 37: ...release mounted on the heat exchanger water inlet is an absolute safety element on the heat exchanger If a fault is present e g all control and safety devices fails and hot water flows at high pres su...

Page 38: ...s Alto Anti Stone level is low Refill Alto Anti Stone Hot water and Cold water mode is possible Red LED illumina tes Pump oil level is low Refill pump oil Chapter F 1 3 The burner and motor are cut ou...

Page 39: ...et the pressure rate control or Vario Press for a higher water flow Descale the machine Green LED and red LED flash si multaneously Leakage or impermissi ble operating status through brief operation S...

Page 40: ...ex tension cable with a lar ger cross section Possibly a phase failure have the electrical con nection checked Correct the cause of the fault Chapter D 2 3 5 and replace the thermal release Chapter F...

Page 41: ...oo low HP nozzle worn Pressure rate control or Vario Press set for too low a pressure Flexo Power nozzle open Replace the HP nozzle Turn the pressure rate control on the unloader valve in the directio...

Page 42: ...F NEPTUNE PE DE_en_Ver 1 0_October 2010 Service Repair 42 NA5 Pump Jetwash Direct ltd...

Page 43: ...g the thrust collar Inspect the thrust collar for damages before mounting Fig F 14 Thrust collar Fig F 13 Valve housing Fig F 15 Valve housing Fig F 16 Valve housing Carefully tip out the sleeves with...

Page 44: ...f the placement of pressure valve parts Take out the pressure valve seats with an adequate puller or use an 8mm threaded pin Replace with new parts if necessary Picture of piston guides The pressure v...

Page 45: ...er block Take out the oil sleeves using an adequate screwdriver Be careful not to damage the surface of the cylinder block Oil seal and piston NEW To make replacement easier moisten the sleeves with s...

Page 46: ...p head Fig F 26 D bearing cover and wobble disc Fig F 28 Wobble disc removal Fig F 27 Wobble disc Demount the wobble disc screwing a 1 6mm bolt into the threads Tighten the bolt against the motorshaft...

Page 47: ...The D bearing cover is mounted to the Motor by four 6mm bolts When the bearing is damaged always replace the complete D bearing cover The oil sleeve in the D bearing cover can be demounted carefully u...

Page 48: ...F NEPTUNE PE DE_en_Ver 1 0_October 2010 Service Repair 48 C3 Pump Jetwash Direct ltd...

Page 49: ...F NEPTUNE PE DE_en_Ver 1 0_October 2010 Service Repair 49 Mandrel no 1216506 C3 Pump Jetwash Direct ltd...

Page 50: ...e Repair 50 Mounting of textile sleeves by means of tool no 1220090 It is an advantage if the sleeves havebeen in a water bath for 3 4 hours before mounting them Do not forget to blow air through the...

Page 51: ...ssage from the drain holes Drain off the oil Loosen the 8 bolts gradually because of the spring load Special box head no 1206762 may be used Mount new O rings on studs with tool no 1206812 Washer O ri...

Page 52: ...it will be a good idea to moisten the sleeves with soapy water Mount new oil sleeves with punch no 1220429 Carefully knock or press them home Oil sleeve LP HP Check the piston for wear in the pressure...

Page 53: ...approx 2000 hours When mounting the D bearing cover comp lete protect the U sleeve with tool no 1206598 which is placed on the shaft befo re placing the cover Tool 1206598 When mounting the wobble dis...

Page 54: ...F NEPTUNE PE DE_en_Ver 1 0_October 2010 Service Repair 54 Valve cover seals Pistons oil seals Pump h ousing Motor NP5 Pump Jetwash Direct ltd...

Page 55: ...unt the brass plug on the cylinder head with a 21mm fixed spanner and remove the valves Do not scratch the inside of the valve chamber during removal When you replace the valves give the o rings an in...

Page 56: ...r remember lubricating When dismounting the suction sleeves use a screwdriver to tip out the sleeves Do not reuse the sleeves Clean the thrust collar and lubricate before mounting the sleeves as shown...

Page 57: ...the plunger rod prior to reinstalling the plungers Also clean the brass slinger plates before reinstalling the plungers Do not re use the copper washers Use one drop of medium strength thread locker o...

Page 58: ...F NEPTUNE PE DE_en_Ver 1 0_October 2010 Service Repair 58 NP5 Unloader valve NP5 Unloader valve parts NP5 Unloader valve NP5 Pump Jetwash Direct ltd...

Page 59: ...ler 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 boile...

Page 60: ...ook up the crane and lift out the coil Check the flame tu be marked with X and Y It is important that they are solid and complete Y is a part of the coil 8 and cannot be se parated Clean the coil 9 Cl...

Page 61: ...e between the legs beco mes greater than 4 mm the electrode must be changed The electrode 18 is self adjusting the position on the nozzle by a spring washer 19 under the fixing screw 20 7 6 13 21 22 4...

Page 62: ...ed Water filters Oil filter Checking the pump oil quality Changing the pump oil Emptying the fuel oil tank NP 5 pump only After the first 50 operating hours C3 and Na5 pump every six months or 500 ope...

Page 63: ...ifications Fig G 01 Wobble disc Fig G 02 Cylinder block Fig G 03 Cylinder head Fig G 04 Venting valve Fig G 05 By pass housing 40 Nm Fig G 08 Water regulation Fig G 07 Outlet fittings Fig G 06 Venting...

Page 64: ...onnect a test tap A hose and pressure gun to the outlet of the machine Close the safety valve completely Adjust the test tap A and the pressure bolt B so it couples 20 30 bars higher than working pres...

Page 65: ...nut Then let the machine run just below the cut off pressure working adjustment and ad just the safety valve out until it couples out go into bypass Then you adjust the ad justing screw a turn back an...

Page 66: ...3 untill you reach approx 30 bar Safety valve adjustment First mount test manometer without test nozzle just open outlet Turn the black handle on the water regulator all the way counterclockwise Max...

Page 67: ...g a screwdriver or similar tool to remove the cap on top of the unloader 13 mm Box spanner Loosen the lock nut on the pres sure adjustment bolt Use a 13 mm box spanner Adjust the pressure with a 7 mm...

Page 68: ...P5 pump When the correct pressure is ad justed tighten the lock nut with a 13 mm Box Spanner Mount the cap on top of the unloader Now the correct adjust ment of the unloader is done By turning the han...

Page 69: ...n 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 Th...

Page 70: ...06 a little and check the soot rating and Co2 content again Fig G 18 Burner measurements Burner settings 1 BR1 2 BR2 3 X5 For Datalogger and Service Interval 4 Fuel LED 5 Antistone LED 6 Service LED 7...

Page 71: ...ustment Test 71 Boiler 4 Flame sensor 5 Fuel nozzle 6 Air distributer Fig F 49 Boiler top 2 1 3 4 5 6 1 Ignition Transformer 2 Ignition cords 3 Ignition electrodes 5mm 4mm Fuel nozzle 5mm Fuel nozzle...

Page 72: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 72 NEPTUNE 5 46PE 1 OF 3 Jetwash Direct ltd...

Page 73: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 73 NEPTUNE 5 46PE 2 OF 3 Jetwash Direct ltd...

Page 74: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 74 NEPTUNE 5 46PE 3 OF 3 Jetwash Direct ltd...

Page 75: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 75 NEPTUNE 5 54 AND 7 61PE 1 OF 3 Jetwash Direct ltd...

Page 76: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 76 NEPTUNE 5 54 AND 7 61PE 2 OF 3 Jetwash Direct ltd...

Page 77: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 77 NEPTUNE 5 54 AND 7 61PE 3 OF 3 Jetwash Direct ltd...

Page 78: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 78 NEPTUNE PE 1 Cylinder Honda Page 1 of 3 Jetwash Direct ltd...

Page 79: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 79 NEPTUNE PE 1 Cylinder Honda Page 2 of 3 Jetwash Direct ltd...

Page 80: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 80 NEPTUNE PE 1 Cylinder Honda Page 3 of 3 Jetwash Direct ltd...

Page 81: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 81 NEPTUNE 5 85PE 1 OF 3 Jetwash Direct ltd...

Page 82: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 82 NEPTUNE 5 85PE 2 OF 3 Jetwash Direct ltd...

Page 83: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 83 NEPTUNE 5 85PE 3 OF 3 Jetwash Direct ltd...

Page 84: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 84 NEPTUNE 5 51DE 1 OF 3 Jetwash Direct ltd...

Page 85: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 85 NEPTUNE 5 51DE 2 OF 3 Jetwash Direct ltd...

Page 86: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 86 NEPTUNE 5 51DE 3 OF 3 Jetwash Direct ltd...

Page 87: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 87 NEPTUNE 7 66DE 1 OF 3 Jetwash Direct ltd...

Page 88: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 88 NEPTUNE 7 66DE 2 OF 3 Jetwash Direct ltd...

Page 89: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 89 NEPTUNE 7 66DE 3 OF 3 Jetwash Direct ltd...

Page 90: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 90 NEPTUNE 7 72DE 1 OF 3 Jetwash Direct ltd...

Page 91: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 91 NEPTUNE 7 72DE 2 OF 3 Jetwash Direct ltd...

Page 92: ...H Wiring diagrams NEPTUNE PE DE_en_Ver 1 0_October 2010 92 NEPTUNE 7 72DE 3 OF 3 Jetwash Direct ltd...

Page 93: ...93 NEPTUNE PE DE_en_Ver 1 0_October 2010 Notes Jetwash Direct ltd...

Page 94: ...JETWASH DIRECT LTD www jetwashdirect co uk sales jetwashdirect co uk Jetwash Direct ltd...

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