Gerni Service Manual

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Gerni Service Manual

The in- sulation of the electric cable should be faultless and without any cracks. Gerni ac- cepts no liability for any damage resulting from such use. The risk for such use is borne solely by the user. Their spray is highly combustible, explosive and poi- sonous. If there is a risk of silt, sand or sediment in the inlet water (i.e. To connected to open con- from a rain water tank as an avoid water spillage, crimp tainers (suction mode)) example. The hose for the wa- the water inlet hose inside ter supply must not be too long, the water and then connect. The nozzle cleaning tool can also be stored on the product. 6.4 Wall storage The pressure washer can be stored on a wall on a special wall hook (optional accessory). Fuse has blown Replace fuse. Switch off other machines. Find your local service er has not been used for agent here: rental nor used com mer cial ly. Please upgrade your browser to improve your experience. Contact tour local Gerni Service centre.. that the directions of the instruction manual have been thor-.To find the right User Manual for your product, use the search field in the top of the page. Or click on the respective Service. Nilfisk Pty Ltd tips and instruc- tions to simplify work and to en- sure safe operation. Operations marked with this symbol should only be car- ried out by Gerni. Service Techni-. View and Download Gerni Classic 120.2 user manual online. Any repair should always be made in Gerni authorized workshop with original Gerni spare parts. Please upgrade your browser to improve your experience and security. We will be back up and running shortly. If you’d like to buy Gerni online you can do that by clicking here and visiting the Bunnings website. If under warranty, please provide the service agent with this information. Used for hot water cleaning in both the light Industrial and the commercial sector, farming and light industrial sector. Everything is in line, resulting in minimum friction loss and requiring a smaller power source.

Page 4 insurance association, social security institutions, occupational safety and health authorities or other organizations. Only use hoses, fittings and couplings recommended by Gerni. Illustration shows the operation elements and how to prepare your machine for use. Detach the high pressure hose by pressing the button (A). Page 9 ? ditional filtering to secure that impurities are not sucked in. Detach the high pressure hose from the outlet. Page 10 6 Maintenance D See the pictorial quick reference guide - maintenance. Page 11 Symptom Machine stops Cause Fuse has blown Incorrect mains voltage Thermal sensor activated Nozzle partially blocked Recommended action Replace fuse. Switch off other machines. Check that the mains voltage corresponds to specification on the model tag. Leave the washer for 5 minutes to cool down. Clean the nozzle (see section 6.2) Fuse blows Fuse too small Change to an installation higher than the amp.You may try without the extension cable. Page 12 The benefits under this warranty are in addition to your national law of sale. Guarantee repairs are made on the following conditions. IndexThis service manual contains a detailed description of the main repair work on the hot HPW. NEPTUNE 5 and NEPTUNE 7. Repair work requires a suitable testing workplace with the necessary power supply. 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 theThey include information on technical modificationsIt is not permitted to give them to third parties. Use original ALTO spare parts only.Safety instructions. Observe valid safety regulationsAdditionally. Also see national regulations.

Repair work should beESD measuresBefore using the cleaner, alwaysOnly allow the high pressureTake the following ESD precautions before carrying out any repairs toWater volume Qmax. Water volume QIEC. Pressure P1 (working pressure). Pressure Pmax. I. Pressure P max. II. Heating power. Electrical data. Current consumption. Fuse (slow blow). International Protection Class. HP-Nozzle. Water inlet pressure. Water inlet temperature. Water volume heat exchanger. Oilpressure. Flue gas temperature. C02 content min. Soot rating. Efficiency burner. Sound pressure 1m. Sound power LWA. Reactive force. MotorPiston diameter. Stroke. Pump oil. Pump oil quantity. Weight. LxWxHNeptune 5-42. Water volume Qmax. LxWxHNeptune 5-49. LxWxHNeptune 5-57. LxWxHNeptune 7-25. W a t e r vo lu m e Q m a x. W a t e r vo lu m e Q IEC. P re s s u re P 1 (w o rk in g p re s s u re ). P re s s u re P m a x. I. P re s s u re P m a x. II. H e a t in g p o w e r. E le c t ric a l d a t a. C u rre n t c o n s u m p t io n. F u s e (s lo w b lo w ). In t e rn a t io n a l P ro t e c t io n C la s s. H P -N o z z le. W a t e r in le t p re s s u re. W a t e r in le t t e m p e ra t u re. W a t e r vo lu m e h e a t e x c h a n g e r. O ilp re s s u re. F lu e g a s t e m p e ra t u re. C 0 2 c o n t e n t m in. S o o t ra t in g. E ffic ie n c y b u rn e r. S o u n d p re s s u re 1 m. S ound power LW A. R e a c t ive fo rc e. M otorP is t o n d ia m e t e r. W o b b le d is c. P u m p o il. P u m p o il q u a n t it y. W e ig h t. L x W x HNeptune 7-63. Wobble disc. LxWxHIn this manual two different models are described: the NEPTUNE 5 and the NEPTUNE 7. The twoVisually they are different on two points - the height of the heat exchanger and the type of motor pumpHeatHeatNP5 motor pumpC3 motor pump. NEPTUNE 7 variants. NEPTUNE 5 variantsExtended versions. Cable reel. Standard models. X-models. X2-models. Hose reelPic. 3.3: Neptune X2-modelService side.

With the service doors open there is free access to all technical parts that require service (Pic.Fuel suction pipe. Fuel gauge. Fuel return pipe. Pressure gauge connection. TemperatureFuel nozzle connection. Temperature sensorPipe for lifting hookIgnition transformer. Exhaust. Fuel tank. Fuel pump. Anti stone valve. Detergent AWater tank. HydraulicControl Safety Block. Pump oiltank. Pic. 3.5: NeptuneWater quantity regulator. Suction connection (filter inside)The frames of Neptune 5 and 7 are identical and built up in a straightforward form, all boltedFuel tank gaugeS to x 1AntiStone tank. Inlet valve. Water tank. Suction hose. Detergent A tankOperator side. The electric box (Pic. 3.8) contains the control board, the transformer, relays, fuses andThe cover plate is mounted with the main switch, the display, the. The cover is sealed around the edge, the manometer and the detergent valve (Pic. 3.7).Fuel. Anti Stone. Service. Display:Main switch S1. Adjust:Pic. 3.6: Operator panel. Sealing. Display board A2. Data plate. S1 mainPic. 3.7: Operator panel (backside). Pic. 3.8: Electrical box. The cover is hinged in the lower left side and secured with a strap to avoid stress on the displayElectric system. The electric control system is built up around the control board A1 (Pic. 3.10) which is dividedThe transformer T1 (Pic. 3.9) supplies the system with 24 VAC and 8 VAC.X7: remote. X2: dataloggerX1bXmbDisplayFuel. Pump Oil. Anti StoneHeat exchanger. The heat exchanger is the heat generating part of a hot water machine. It consists of a labyrinthconstructed tube coil, which encloses the combustion chamber. The tube coil is enclosed by aAn insulating material placed in theElectrodes. Flame sensor. Fuel nozzle. Air distributor. Water inlet. Water outlet. Burner tube top plate. Flame tube top part. Burner tube. Outer jacket. Flame tube. Inner jacket. Fixation spacerIsolation (firebrick). Isolation (ceramic fibres).

Note the heat exchanger tube arrangement in the the outer circle where the tube change positionThe four piston axial pump C3 used in the Neptune 7 models is a compact unit with motor andOil. KeOut. PressureIn. SuctionFan. Stator. Rotor. Piston. The three piston radial pump NP5 used in the Neptune 5 models is a compact unit with motor andCrankshaft. Out. Oil. Pressure valve. Motor. Motor shaftIn. Suction valveOperation. Display. Start cold water mode. Start hot water mode. Main switch S1. Temperature setting. Suction from pump. Status indicators. Pic. 4.1: Operator panel. Pressure gauge. DetergentIf the machine and power supply are o.k. (depending on the electronic set-up) following willWhen the main switch S1 is turned on to cold or hot water mode, the machine runs a self test (3Optionally it’s possible to show the actual running hours of theAfterwards the motor will start building up pressure until cut off pressure and then by-pass for 20 sThe status indicator lights up the green light on the plug icon only and the pressure gauge showsNow 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 is activated, the pump will deliver water. At the same time the fan for theThe water temperature will now raise until the setpoint has been reached. The combustion stops,The detergent valve makes it possible to choose between detergent A from the built in tank orWith the valve in off position as shown it draws in water from theWhen the machine is running in hot water mode the fan draws in air and leads it into the side ofOn the way, theThe cold water enters the boiler at the inner winding where the temperature is highest. By doingIn hot water mode fuel is drawn from the tank through the fuel filter to the pump.

If combustion isThe ignition transformer is active in hot water mode and it will form sparks between theWhen the machine and heat exchanger are operating properly the flame touches against theC3 pump. The C3 four piston axial pump used in the NEPTUNE 7 models. The four ceramic pistons are driven by a wobble disc which transforms the rotating power from theThe angle of the disc and the diameter of the pistonsThe inlet and the outlet are connected directly to the Control Safety Block.NP5 pump. The NP5 three piston radial pump used in the Neptune 5 models. Crankshaft. Motor shaftThree pistons are driven by connecting rods which are attached to a crankshaft which is, in turn,The eccentricity of the crank (A) and the diameter of the pistonsThe inlet and the outlet are connected directly to the Control Safety Block.Control Safety Block 1. Fine adjustment screw. Low volume adjustment. HP hose to boiler. Main ajustment nut. Low volume spring. Flow switch B2. NO. Unloader spring. Magnet pistonNon-return valve. Unloader valve piston. Safety valve. Unloader valve seat. HP outlet from pump. Water inlet suction sideThe pressure rises until the cutoff pressure is reached (set by theAlso during the initial start, water isWhen the spray gun trigger is squeezed, the pressure trapped inYou can also see in this drawing that the magnet piston hasThe safety valve will only open if the pressure in the systemControl Safety Block 2. There are four purposes of the Control Safety Block:Safety valve. Cut Off Pressure. By-pass pressure. Pum. Working pressure.Starting pressureMounted with an 0680 nozzle and connected to a hoseA: The pressure is building up until the unloader valveThe pressure will rise a little more but will dropPoint DThe pressure drops a little more, but will build up untilAs long as the spray handleB1: Temperature sensor at the outlet of the heat exchanger.B2: Flow switch senses the flow out of the pump into the heat exchanger and with B1, controls.

B3: Safety thermal switch placed at the inlet to the heat exchanger. Switches off the machine, if. Will switch off, if the burner keeps burning without waterWhen pressure is higher than working pressureB6: 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, theB8: Level switch AntiStone 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. Actors. T2: Ignition transformer is on when burner fan is running.Electric system. The machine is supplied with main power which is transformed into 8 VAC to supply theTo run the machine on hot water the following must be o.k.: on the front panel S1 and theIf all the sensors are closed and o.k. K1Y1 will open and let in fuel to the combustionXmbB2: Flow switch. B3: Safety thermal switch. B4: Microswitch. B6: Oil level switch. B7: Flame sensor. B8: AntiStone level switch. B9: Fuel level switch. MT: Motor temp. switch. S1: Main switch. T2: Ignition transformer. Y1: Solenoid valveKerosene can be used only inIf these requirements are met and you still experience operational break-downs, there are faultsCheck list. When trouble-shooting it will be a great help if you can locate the fault as being either anExternal faults usually represent the following. The below-mentioned conditions have been checked and found ok. Yes No. CommentsThe internal faults require a systematic inspection of the motor pump by an ALTO technician. InError codes. Symptom. Hot Safety temperature switch B3Pump Oil Low. Switch B6 open. Cause. Outer. Flow and pressureOil residue in heatHeat exchangerSwitch B3 must beWire defective. Oil seals worn out. B6 switch. Pump pressure tooWire defective. Flow Failure. Flow switch B2 closed and B4 open. No Light, Fuel Enabled. Light sensor B7 sees no flameWire defective. Spark failure.

Oil filter blockedFuel Empty. Level switch B9 Open. Wire defective. Leakage. Three times start without flow. Leaky system. Microprocessor failure. Water in electricTemperature Sensor (B1) Open. Temperature Sensor (B1) Closed. Flow switch open (B2) andAir in suction water. No water. Check. Use of long hoses atLight sensor B7 sees Light. Sensor not in place.Wire defective. Flame sensor short circuitHot Motor Protector. Inner. Oil residue in heat Oil pressure.Electrode. Y1 Leaky. Ignition failure. Fan on motorFuse (F1). Sensor inFlow piston hanging Reed switch. Flow switch off. Fuse (F11). Sensor B7. Leaky non-returnB4 switch. Detergent valve.Electrical tests. Before you change the control board run through these tests:Turn to cold. Stand-by.Start relay to power up the burner. Stop the Machine. Turn switch to start and furtherNB: this test must be carried outDisconnect machine from mains power. Power off. Pressure O. O.k. If not o.k. check,X Connection to coil A1-A2The symptom is reduced performance of the pump effect or the heat exchanger effect. TheScale deposits in heat exchanger tube. Scale formation acts as insulation and reduces heat transfer to the water. The result is raised. Cause: The hardness of the water, no AntiStone or AntiStone dosing too low. Remedy: Descale heat exchanger tube. Sooted heat exchanger tube. Soot has the same effect as scale deposits, i.e. that they are both insulating against the heat. 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. Remedy: Check fuel pressure and quality. Replace the fuel nozzle. Adjust air diffuser. Cause 3: Unfinished combustion. Remedy: Check bottom insulation, boiler top gasket between tube and inner heat exchangerCause 4: Unstable ignition. Remedy: Check electrodes. Adjust the air quantity (less air). Cause 5: Leaky solenoid valve on pump Y1. Low fuel pressure.

Cause 1: Incorrect adjustment. Remedy: Adjust pump pressure (12 bar, see page 50).