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Neptune_GB_Ver.2.0 10/03

_

6.

Service / Repair

Piston & oilseal

Hexagon nut
Torque 13 Nm

To inspect the plunger for cracks:

Spray the inside of the plunger with fast evaporating cleaner such as a brake cleansing agent.
The brake cleansing agent will take a second longer to evaporate from the crack, thus making
the crack visible.

Carefully inspect and replace as needed O-Rings
and support rings on the plunger rod prior to re-
installing the plungers.

Support ring

O-Ring

Packing ring

Distance spacer

Also clean the distance spacer before re-installing the plungers.

Do not re-use the packing rings!

Use one drop of medium strength thread locker on each plunger rod when re-installing hexagon
nut and a torque of 13 Nm.

Oil seals must be changed if there are any signs of leaks or if they are removed. The
recommended way to remove the oil seals which are pressed into the pump body is to puncture
the seal with an awl and pry down.
When installing new seals, a light coating of lubricant on the seals may ease the installation.
Make sure it is pressed in using equal pressure around the entire circumference.

Oil seal

42.

Содержание Neptune 5

Страница 1: ...NEPTUNE 5 NEPTUNE 7 Service Manual...

Страница 2: ...echnical data 3 8 3 Construction 9 15 4 Function 16 23 5 Trouble shooting 24 25 6 Service Repair 26 42 7 Adjustment Test 43 53 8 Wiring diagrams 54 56 9 1 Safety instructions 2 Special tools Spare par...

Страница 3: ...ustrated spare parts lists during repairs They show the assembly position and the sequence in which the individual components should be assembled See Service Technical Information sheets They include...

Страница 4: ...its use and who have been explicitly authorized to use it Repair work should be carried out by persons instructed in electrical installations or by trained electricians only ESD measures electrostatic...

Страница 5: ...umption A 13 14 8 Fuse slow blow A 16 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0530 NT 0450 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger...

Страница 6: ...ion A 15 8 9 1 Fuse slow blow A 20 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0450 NT 0450 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l...

Страница 7: ...21 7 12 5 Fuse slow blow A 25 16 International Protection Class IP X5 IP X5 HP Nozzle NT 0550 NT 0550 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 4 78...

Страница 8: ...6 International Protection Class IP X5 IP X5 HP Nozzle NT 0550 NT 0550 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 4 78 4 78 Fuel consumption dt 45K kg...

Страница 9: ...um ption A 13 F us e s low blow A 13 International P rotec tion C las s IP X5 H P N oz z le N T 0550 W ater inlet pres s ure bar 10 W ater inlet tem perature C 40 W ater volum e heat ex c hanger l 4 7...

Страница 10: ...International Protection Class IP X5 IP X5 HP Nozzle NT 0680 NT 0680 Water inlet pressure bar 10 10 Water inlet temperature C 40 40 Water volume heat exchanger l 6 12 6 12 Fuel consumption dt 45K kg...

Страница 11: ...1 phase 5 25 5 27 3 phase 5 42 5 49 5 57 Extended versions Standard models basket for accessories X models hose reel X2 models hose reel cable reel Pic 3 3 9 Pic 3 1 Neptune 7 C3 motor pump heat exch...

Страница 12: ...draulic accumulator Anti stone valve Suction connection filter inside Water quantity regulator Pump oiltank Detergent A B valve Exhaust Detergent A B suction hose Fuel tank Detergent A tank Water tank...

Страница 13: ...1l Fuel tank Detergent A tank Fuel tank gauge Fuel return pipe Fuel suction pipe Water tank Suction hose AntiStone tank Inlet valve B9 Frame 5 7 The frames of Neptune 5 and 7 are identical and built u...

Страница 14: ...nnection terminals The cover plate is mounted with the main switch the display the temperature adjustment and five status warning lights Pic 3 6 The cover is sealed around the edge the manometer and t...

Страница 15: ...F11 13 14 11 14 24 8 6 5 4 1 2 3 X11 MT Xma Xmb 9 7 Xma Xmb T2 M 1 M2 O N 1 2 X7 remote B8 B4 B6 B1 B9 S1 B7 K 1 K 2 Y 2 Y 1 B 2 M T B 3 2 4 V 8 V Electric system K1 K2 Fuse F2 Fuse F1 X2 datalogger...

Страница 16: ...he combustion chamber An insulating material placed in the bottom of the heat exchanger makes sure that the inner bottom among other things is protected from superheating Water inlet Air distributor F...

Страница 17: ...valve Oil Oil Motor shaft Crankshaft Motor Piston In Out Suction valve Pressure valve 15 Pump 7 5 The four piston axial pump C3 used in the Neptune 7 models is a compact unit with motor and pump buil...

Страница 18: ...he plug icon only and the pressure gauge shows max pressure Now the machine is on stand by in cold water mode By switching to hot water mode the machine remains in stand by mode When the spray handle...

Страница 19: ...lt code will be shown on the display When the machine and heat exchanger are operating properly the flame touches against the insulated bottom The temperature is here approximately 1100 C The hot exha...

Страница 20: ...are driven by a wobble disc which transforms the rotating power from the rotor into the reciprocating pump pistons The angle of the disc and the diameter of the pistons decide the volume of water suc...

Страница 21: ...y of the crank A and the diameter of the pistons decide the volume of water sucked into the suction valves and pressed out through the pressure valves The inlet and the outlet are connected directly t...

Страница 22: ...is pressurized in the heat exchanger the high pressure hose and the HP chamber under the unloader valve piston When the unloader valve opens there is a lower pressure in the green area and the non re...

Страница 23: ...microswitch B4 closes and starts the motor The pressure drops a little more but will build up until the working pressure approximately 165 bar in this example is reached As long as the spray handle is...

Страница 24: ...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 of the flame If the flame is not detected when it should be the...

Страница 25: ...sensors and 24 VAC to supply the actors contactor relay solenoid valve To run the machine on hot water the following must be o k on the front panel S1 and the temperature setting on hot and the spray...

Страница 26: ...motor thermal protection switch may open and stop the motor 5 Variation in the mains voltage supply must be within 7 of the rated value at the machine long or undersized extension cords can be a prob...

Страница 27: ...too hot 13 Fuel filter blocked 14 Air adjustment faulty 15 Fuel level low or water in fuel tank The require a systematic inspection of the motor pump by an ALTO technician In order to establish the re...

Страница 28: ...ensor not in place Wire defective Oil residue in heat exchanger is burning Y1 Leaky Ignition failure Oil pressure Nozzle Electrode Flame sensor Ho M P t otor rotector Motor winding 160 C 320 F Pump pr...

Страница 29: ...tion Connections in motor plug Change sensor B3 Transformer Transformer Level switch anti scale Micro switch setting Level switch oil Temperature sensor Level switch in fuel tank Go to power On Check...

Страница 30: ...eased flue gas loss Other symptoms are that the machine smokes after it is warmed up during steady operation Cause 1 Air deficiency Remedy Check air adjustment and fan attachment to heat exchanger Cau...

Страница 31: ...ending on the actual consumption A test of the water pressure should therefore be carried through when there is a heavy consumption The pressure must under no circumstances drop below 1 bar NB If the...

Страница 32: ...Neptune_GB_Ver 2 0 10 03 _ 6 Service Repair Ke nn ey C3 Survey Unloader valve Page 31 Cylinder head Page 32 33 Cylinder block Page 34 35 Motor and wobble disc Page 36 37 30...

Страница 33: ...m 2 25 Nm 18 24 Control Safety Block 31 The safety valve has been set at the factory and can t be adjusted Check that the printed pressure corresponds to the specification B2 If any pitting or scratch...

Страница 34: ...the casting smile Tighten the eight 10 mm nuts with 27 Nm Dismount suction valve seat with a mandrel Now press out the pressure valve with a 2 mm punch Check the surface of the seats Mounting only by...

Страница 35: ...bath for 3 4 hours before mounting them Do not forget to blow through the ducts and grease all sleeves before mounting Don t scratch the brass cylinder head when removing the old HP sleeves 33 Duct D...

Страница 36: ...Rings over the threads will cause oil leaks Always replace LP sleeves when replacing HP sleeves Check that the ducts are clear Kit 16 consists of two new parts the crown back up ring and the thrust c...

Страница 37: ...emove any coating Before mounting the new sleeves it will be a good idea to moisten the sleeves with soapy water Mount new oil sleeves with punch P N 1220429 Carefully knock or press them home Careful...

Страница 38: ...al legs P N 1206150 1206168 Pic 6 7 Do not forget to remove key 5 before dismounting the D bearing cover Check bearing surfaces for wear If in doubt replace kit completely after approximately 2000 hou...

Страница 39: ...with tool P N 1206598 which is placed on the shaft before placing the cover Check the bearing surfaces for wear As long as the surface is even and shiny without pitting or grooves the wobble disc can...

Страница 40: ...Neptune_GB_Ver 2 0 10 03 _ 6 Service Repair Valve cover seals Page 40 41 Pistons oil seals Page 42 Pump h Page 43 ousing Motor Page 43 NP5 Survey 38 Control Safety Block Page 39...

Страница 41: ...3 7Nm 2 Control Safety Block The safety valve has been set at the factory and can t be adusted Check that the printed pressure corresponds to the specification 25 Nm 39 B2 If any pitting or scratches...

Страница 42: ...ing Pic 6 13 Pressure valve Pic 6 14 Suction valve Dismount 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 re...

Страница 43: ...Pic 6 17 Removing LP sleeve 3 When dismounting the LP sleeves use a screwdriver to tip out the sleeves Pic 6 17 Do not re use the them 6 When you mount the cylinder head tighten the bolts in the show...

Страница 44: ...ing O Ring Packing ring Distance spacer Also clean the distance spacer before re installing the plungers Do not re use the packing rings Use one drop of medium strength thread locker on each plunger r...

Страница 45: ...windings have burned or broken 2 Cable connection from motor plug to stator has been broken 3 Flash over to frame 4 Bearings abnormally worn Pump house motor Replace the pump X completely if 1 The pum...

Страница 46: ...on the floor press over to the side Pic 6 23 or protect the machine with a piece of cardboard Check the flame tube X and Y It is important that they are solid and complete Parts X and Y are part of th...

Страница 47: ...ert remove the whole unit Don t forget to bring back float switch to operating position A after and make sure that the seal is in place 45 Pic Electrodes fuel nozzle 6 26 Pic Electrodes fuel nozzle 6...

Страница 48: ...into the pump 1 Unscrew Quick GEKA coupling 2 Remove filter with tool and clean it 3 Clean filter at the pump inlet hose 1 Unscrew filter cap 1 2 Clean replace oil filter 2 3 Dispose of cleaning solut...

Страница 49: ...fter 20 min in by pass mode Arestart is only possible with mainswitch S1 At the same time the ouput of the optional valve Y2 gets power for 10 s to release pressure at the HPoutlet Change temperature...

Страница 50: ...to right Remove adjustment knob after removing cap not shown in Pic 7 2 it s on top of the adjustment knob Turn setscrew 7 to left until it no longer contacts intermediate piece 2 Dismount setscrew 5...

Страница 51: ...on nut 8 counterclockwise Then turn union nut 8 to right until it contacts adjustment screw 1 Close gun and check function of microswitch 3 Lock union nut 8 with lock nut 6 Lock lock nuts 6 and 9 and...

Страница 52: ...ch and a torque of 18 Nm 6 Disconnect fuel pressure gauge Caution Fuel nozzle Part number NEPTUNE 5 25 27 7 25 1 35 60 H 301001068 NEPTUNE 5 42 49 57 1 75 60 H 301000886 NEPTUNE 7 63 2 50 60 H 3010008...

Страница 53: ...ster accumulation of soot on the heat exchanger coil 2 Caution The values dictated by National Emmissions Control Ordinances have to be kept By adjusting the air flap the soot CO and O values change W...

Страница 54: ...8 3 6 7 5 7 14 8 8 17 5 12 5 25 1 51 150 moderately hard 2 2 3 128 180 7 6 10 5 14 21 17 5 26 3 25 1 37 6 151 300 hard 3 3 4 180 10 5 21 26 3 37 6 300 very hard 4 4 The ALTO AntiStone device is set at...

Страница 55: ...red line Three of the motor wires are connected in a star point thick purple line The burner motor and ignition transformer are connected to this star point and therefore supplied with 230 V only The...

Страница 56: ...X5 11 X5 7 X4 9 X4 5 U2 V2 W2 M 3 V1 W1 U1 M1 F11 13 14 11 14 24 8 6 5 4 1 2 3 X11 MT Xma Xmb 9 7 Xma Xmb T2 M 1 M2 71246 54 Switch on off Control transformer Ignition transformer Connector display bo...

Страница 57: ...A1 A2 K2 3 K3 X12 C1 X11 2 11 14 24 4 C2 R1 X13 Xma Xmb 2 4 8 3 1 71250 1 phase 55 Control board Display board Temp sensor Flow switch Safety thermal switch Micro switch Level switch pump oil Light se...

Страница 58: ...2 K1 1 0 2 S1 8a 7a 6a 5a 4a 3a 2a 1a 1 2 3 4 5 6 8 7 K1 S2 F11 11 14 24 1a 2a 2 1 7 6 MT 7 9 Xma XMb Xma XMb 3 1 2 4 5 6 8 71261 3 Star Delta 56 S1 S2 T1 T2 X3 X6 X2 X3 X6 X7 X11 Xma b Y1 Switch on o...

Страница 59: ...r spare l l 17239 Soot comparison chart l l 17241 CO2 test liquid l l 17242 Exhaust air thermometer Manual l l 17243 Measurement suitcase l l 17246 Oil pressure testing l l 17249 CO2 measurement equip...

Страница 60: ...001130 Extension kit hose cable reel l l 301001131 Extension kit cable reel l l 301001146 Piston kit dia 18 l 301001147 Piston kit dia 20 l 301001148 Piston sealing kit dia 18 l 301001149 Piston seali...

Страница 61: ...e Neptune 5 Neptune 7 41455 Grease 15 C till 130 C 50 g tube l l Further material Table 9 3 Further material To lubricate sleeves O Rings and other parts always use the grease in table 9 3 Never use g...

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