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

Nilfisk
ALTO Index
Index
Preface ... 1

A. Safety Instructions ... 2

B. Technical Data
1. Neptune 8-103 *EU* ... 3

C. Construction ... 4

D. Function
1. Soft start ... 7

E. Troubleshooting ... 8

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 ... 14

H. Wiring Diagrams
1. Wiring diagram parts list ... 15
2. 3~ star (71342) ... 16

I. Special Tools / Spare Parts ... 17

Notes ... 18

Neptune 8_EN_Ver.1.0_01/05
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ALTO 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 original Nilfisk ALTO spare parts only!

Neptune 8_EN_Ver.1.0_01/05 1/21

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ALTO 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

Before starting the equipment, be sure to

Repairs should only be
made by someone who
has received proper
instructions for the job or
who is a qualified
electrician.
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 Observe the following ESD precautions before any repair of or near
discharge) electronic parts:

l Touch the protective conductor to discharge your own body.

l Possibly wear an anti-static wrist strap.

l Use a conducting floor or tabletop.

l Never touch a circuit board or electronic components always hold

it by the plastic or insulation.

l Transport electronic parts in conductive packaging (e.g. special

ESD packages).

Neptune 8_EN_Ver.1.0_01/05 2/21

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ALTO Technical data B
1. NEPTUNE 8-103
N e p tu n e

NEPTUNE 8 8 -1 0 3
*E U *

M a c h in e p ro te c tio n c a te g o ry IP X5
C u rre n t c o n s u m p tio n A 2 2 ,4
V o lta g e V 400 - 415
Technical machinedata

F re q u e n c y Hz 50
C o n n e c te d lo a d kW 12
S o u n d p re s s u re d B (A ) 8 0 ,2
H P n o z z le 1200
P re s s u re P 1 / P 1 m a x . bar 180 / 250
P re s s u re P 2 / P 2 m a x . bar 25 / 32
M a x . re c o il fo rc e N 103
W a te r th ro u g h p u t (m a x .) l/h 2000
W a te r th ro u g h p u t (E N 6 0 3 3 5 -2 -7 9 ) l/h 1950
W a te r in ta k e p re s s u re (m a x .) bar 10
W a te r in ta k e te m p e ra tu re (m a x .) °C 40

V o lta g e V 230 - 400

F re q u e n c y Hz 50
Motor

C o n n e c te d lo a d kW 11
M o to r in s u la tio n CL. F
In g re s s p ro te c tio n IP 44
RPM U /m in 1450

T ype N 8 3 0 .2 0
P lu n g e r c e ra m ic
Pump

P lu n g e r d ia m e te r mm 22
P lu n g e r s tro k e mm 1 9 ,8
P u m p o il SAE 15 W 40
A m o u n t o f o il ml 2150

F u e l p re s s u re bar 1 2 ,5
F u e l c o n s u m p tio n d t = 4 5 K k g /h 6 ,0
Heat exchanger

E x h a u s t te m p e ra tu re °C 185
C O 2 c o n te n t (m in .) % 1 0 ,5 (+ 0 ,8 )
S o o t ra tin g 0 - 1
E ffic ie n c y % > 92
W a te r c o n te n t (c o il) l 6 ,1 2
H e a tin g p o w e r kW 115

L e n g th mm 1190
sionsand
Dimen-

weight

W id th mm 702
H e ig h t mm 1020
W e ig h t kg 228

H ig h -p re s s u re h o s e m 10
Miscella-
neous

E le c tric a l le a d m 5
F u e l ta n k l 35
D e te rg e n t ta n k l A: 15 / B: 10
Table B.1: Neptune 8-103

Neptune 8_EN_Ver.1.0_01/05 3/21

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ALTO Construction C
Construction
The outer design of the Neptune 8 hot-water high-
5 pressure 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

Due to the higher performance specifications of the

Neptune 8, the main differences to the Neptune 5 / 7
1 series are found in a modified, larger dimensioned
motor/pump unit. In detail, this results in the following
constructional differences:
2
-soft start (1) for the pump motor
-pump motor (2) without attachment plug
-pumping set (3) with modified water and detergent
intake
4
In addition to the basic design changes from the
3 Neptune 5 / 7 series listed above, there are further less
evident constructional differences:
Fig. C.2: Neptune 8-103 with cover hood and side
panel removed - 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 3.) Pumping set (N8) 5.) Storage tray
2.) Pump motor 4.) Control safety block
Neptune 8_EN_Ver.1.0_01/05 4/21
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ALTO Construction C
Construction
Soft start of the pump motor

4 The soft start electronic circuitry is located in a separate

3
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.
2
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

Due to the higher current consumption compared to the

6 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

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
10 (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
10 9
to the valve block (8) at the motor side.
7
8 For further details see Chapter F.2.
Fig. C.5: Pumping set (N8)

Fig. C.3 - C.5:

1.) Soft start housing 5.) Motor 9.) Valve block

2.) Soft start housing bracket 6.) Motor line 10.) Water feed hose
3.) Central tube 7.) N8 pump
4.) Connecting line 8.) Support foot
Neptune 8_EN_Ver.1.0_01/05 5/21
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ALTO Construction C
Construction
Control safety block

The following modifications were made to the control safety block

1
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
2 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
3 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
6 also different.
5
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 3.) Float valve 5.) Float

2.) Housing 4.) Water inlet filter 6.) Membrane
Neptune 8_EN_Ver.1.0_01/05 6/21
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ALTO 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.
A1

12
PE L1 L2 L3
Datalogger 5V DC F1 T1 S1
X4-21 11 7
X2 + ~

1a
8V AC
X4-23 12
B1 400V AC
X5-13 X4-17 13
X5-15 24V AC
X4-19 14 4
X5-5

2a
B4 X4-15

2
P B3
X4-13
X5-7
X5-9 X4-9
MT
B6 F2
X4-11
X5-11

X3-1
B7 X6-9
µP
A1 13 5 13

X6-11 K1
X3-9 A2 24 6 14
X5-1
B8
X3-5
F11
X5-3
X4-5
B2
X6-1 Q
B9 X4-7
A1 11
K2
A2 14, 24
X6-3
A3
X4-1
X6-6
Y1
S1 4
L1 L2
M2 T2
M
T1 T2 1~
4a X4-3
X3-7
X6-7
X3-3
X3-11
X1a
X1b X7 X11 X12 X13
Remote

A2
Temp. Display U1 V1 W1
M1 M
3~
U2 V2 W2
Operation Fuel Pump Oil Service Anti Stone

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.

Fig. D.2: Neptune 8 soft start board

Fig. D1 & D2:

1.) Potentiometer
Neptune 8_EN_Ver1.0_01/05 7/21
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ALTO 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

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ALTO Maintenance / repair F
1. Maintenance
Maintenance plan
Every 6 months
After the first 50
Maintenance task Weekly or 500 operating As required
operating hours
hours
Cleaning water filter
Cleaning oil filter
Checking pump oil
quality
Changing pump oil
Emptying fuel tank
Flame sensor
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

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
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ALTO Maintenance / repair F
2. HP pump (N8)
1. Survey

6
4

3
1

4
5
2

Fig. F.2: HP pump of Neptune 8 (exploded view)

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
7 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
4
the NP5 HP pump.) They ensure smooth operation and
2 long service life.
Multigrade oil is used for lubrication of the HP pump.
(Note: About 2150 ml are required for the NP8 pump vs.
Fig. F.3: HP pump of Neptune 8 (sectional model) 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) 3.) Crankshaft 5.) Collar set

2.) Pump housing 4.) Roller bearing 6.) Pump connecting rod
Neptune 8_EN_Ver1.0_01/05 10/21
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ALTO Maintenance / repair F
2. HP pump (N8)
2. Thrust collar set
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

Low-pressure package:
4 4.) Support ring (not shown in lower part of Fig.
8
F.4)
5.) Low-pressure sleeve
1 2 3 5 7 6.) Low-pressure thrust collar
6
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
The three connecting rods (9) in the N8 HP pump
are designed in two parts. Before removing the
A crankshaft (10) unscrew the hexagon screws
A (arrows A) and remove them together with the
A 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
9 to lubricate the bearing faces of the rods (9) and
10
9
not to jam the rods. Tighten the fastening screws
A 9
(arrows A) alternately and evenly.
A
A

Fig. F.5: Pump housing opened (view from the rear)

Fig. F.4 & F.5:

1.) Support ring 4.) Support ring 7.) O-ring 10.) Crankshaft
2.) HP sleeve 5.) LP sleeve 8.) Oil seal (piston)
3.) HP thrust collar 6.) LP thrust collar 9.) Pump connecting rod
Neptune 8_EN_Ver1.0_01/05 11/21
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ALTO Maintenance / repair F
2. HP pump (N8)
4. Torque values

F C
2

G
1

E
B

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
Nilfisk
ALTO Maintenance / repair F
3. Electric system
1. Soft start
The soft start circuitry is located in a housing (1)
mounted on a bracket (2) clamped to the central
5 3 tube (3) of the machine.
4
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
A
the mains plug.
Before removing the complete soft start box
including its bracket (2), turn off and unplug the
2
machine. Then, as required, disconnect the
connecting line (5) of the electronic circuitry
1 (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
Fig. F.7: Soft start housing mounted to central tube central tube (3). For further details about
assembly, refer to the corresponding spare parts
list.

2. Motor supply line

The motor line (6) is connected without an
attachment plug to the motor (7). Therefore, the
motor (7) must be disconnected at the electric
6
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
7 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 3.) Central tube 5.) Connecting line 7.) Motor
2.) Bracket 4.) Housing cover 6.) Motor supply line
Neptune 8_EN_Ver1.0_01/05 13/21
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ALTO Adjustments G
Adjustments
Electronic circuitry: Adjustments see Neptune 5 / 7 Service Manual.

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
CO2 content % 10.5 (+ 0.8)
Fuel pressure bar 12,5
Soot rating 0-1

Flow control: Adjustment procedure see Neptune 5 / 7 Service Manual.

AntiStone device: Parameters for adjustment see Neptune 5 / 7 Service Manual. (Neptune 8 is
set similar to Neptune 7.)

Soft start: 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

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ALTO Wiring diagrams H
1. Wiring diagram parts list
Note:
The components listed in Table H.1 relate to the following Neptune 8 wiring diagram.

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

 A1

12
PE L1 L2 L3
Datalogger 5V DC F1 T1 S1
X4-21 11 7
+ ~

1
X2

1a
ALTO
8V AC
X4-23 12
Nilfisk

B1 13 400V AC
X5-13 X4-17
X5-15 24V AC

Neptune 8_EN_Ver.1.0_01/05
X4-19 14 4

2
2a
X5-5 X4-15
B4
P B3
X4-13
X5-7
X5-9 X4-9
MT
B6 F2
X4-11
X5-11

X3-1
B7 X6-9
µP
A1 13 5 13

X6-11 K1
X3-9 A2 24 6 14
X5-1
B8
X3-5
F11
X5-3 B2
X4-5
X6-1 Q
B9 A1 11
X4-7
K2
A2 14, 24
X6-3
A3
X4-1
X6-6
Y1 L1 L2
S1 4 M2 T2
M
T1 T2 1~
4a X4-3
X3-7
X6-7
X3-3
X3-11
X1a
Wiring diagrams

X1b X7 X11 X12 X13

Remote

A2
Temp. Display U1 V1 W1
M1 M
3~
U2 V2 W2
Operation Fuel Pump Oil Service Anti Stone

Fig. H.1: Wiring diagram three-phase star

H

16/21
2. Three-phase star (71342)
Nilfisk
ALTO Special tools / spare parts I
Special tools / spare parts / service accessories
Part number Description Remarks
Special tools (1)
Soot pump with filter paper and soot
17237
rating scale
17238 Filter paper
17239 Soot rating scale
17240 CO2 meter with refill fluid
17241 CO2 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
(2)
Spare parts / repair kits
301000911 Safety valve
301002071 Repair kit CSB
310001130 Attachment set: hose & cable drum
301001131 Attachment set: hose drum
301002050 Kit piston 22 mm
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
(3)
Service accessories
Grease (-15 to +130°C), 50 g tube; food-
41455
safe
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

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ALTO Notes
Notes

____________________
____________________
____________________
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____________________
__________________________
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__________________________
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__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
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ALTO Notes
Notes

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__________________________
__________________________
__________________________
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ALTO Notes
Notes

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__________________________
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ALTO Notes
Notes

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