Nanni N16.900 CR3 Operator'S Manual Download Page 59

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S08

MAINTENANCE

SUMMARY

Table des matières

S08

MAINTENANCE

SUMMARY 59

ABOUT 60

GENERALITIES 61

MAINTENANCE 61

MAINTENANCE INTERVALS

TURBOCHARGER 63

TURBOSERVICE 63

LUBRICATION SYSTEM

OILS 64

CHECKING THE OIL LEVEL

CHANGING THE OIL

MAXIMUM ANGLES OF INCLINATION DURING OPERATION

CLEANING THE CENTRIFUGAL OIL CLEANER

OPERATIONAL TESTING OF THE CENTRIFUGAL OIL CLEANER

RENEWING THE OIL FILTER

AIR CLEANER

REPLACE THE AIR CLEANER FILTER AND SAFETY CARTRIDGE

COOLING SYSTEM

CHECKING THE COOLANT LEVEL

CHECKING THE COOLANT ANTI FREEZE AND CORROSION PROTECTION

CHECKING THE SACRIFICIAL ANODES

CHECKING THE SEA WATER PUMP IMPELLER

DRAINING THE SEA WATER PUMP IMPELLER

REMOVING THE CHARGE AIR COOLER

CLEANING THE CHARGE AIR COOLER

REMOVING THE HEAT EXCHANGER

CLEANING THE HEAT EXCHANGER

FITTING THE HEAT EXCHANGER

FITTING THE CHARGE AIR COOLER

FILLING COOLANT

FUEL SYSTEM

DRAINING AND RENEWING THE DUAL WATER SEPARATING PREFILTER

DRAINING AND RENEWING THE SINGLE WATER SEPARATING PREFILTER

DRAINING THE REVERSIBLE WATER SEPARATING PREFILTER

RENEWING THE REVERSIBLE WATER SEPARATING

PREFILTER 84

RENEWING THE COMMUTATIVE FUEL FILTER, 16 LITRE MARINE ENGINE WITH XPI

RENEWING THE FUEL FILTER

VENTING THE FUEL FILTER

CHECKING THE DRIVE BELT

GENERAL TIGHTENING TORQUES FOR SCREWS JOINTS

Summary of Contents for N16.900 CR3

Page 1: ...NANNI MARINE ENGINE OPERATOR MANUAL DGBXXT09019 ENGINE N16 900 CR3 N16 1000 CR3 N16 1100 CR3 N16 1150 CR3 N16 1200 CR3 ...

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Page 3: ...HANGES TRACKED CHANGES CODE INDEX DATE INITIALS NATURE OF TRANSLATIONS PAGES DGBXXT09019 08 2020 LB MC Create Please note all changes and pages associated For further clarity please add a line in front of each change ...

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Page 5: ...S SAFELY 15 PREVENT BATTERY EXPLOSIONS 16 FROST PROTECTION WINTERIZATION 16 LIVE WITH SAFETY 16 PREVENT ACCIDENTS 16 S03 FLUIDS 17 SUMMARY 17 COOLANT 18 ANTIFREEZE CORROSION PROTECTION 18 TABLE IN LITRES C 21 TABLE IN U S GALLONS F 22 ENGINE LUBRICANTS 24 FUELS 26 HVO 27 GTL 27 WATER IN FUEL 28 S04 ENGINE WARRANTY 29 ENGINE IDENTIFICATION 29 ORIGINAL SUPPLIER ENGINE PLATE 29 ENGINE HOMOLOGATION 30...

Page 6: ...2 CHECKING THE SEA WATER PUMP IMPELLER 73 DRAINING THE SEA WATER PUMP IMPELLER 74 REMOVING THE CHARGE AIR COOLER 74 CLEANING THE CHARGE AIR COOLER 75 REMOVING THE HEAT EXCHANGER 76 CLEANING THE HEAT EXCHANGER 77 FITTING THE HEAT EXCHANGER 78 FITTING THE CHARGE AIR COOLER 79 FILLING COOLANT 81 FUEL SYSTEM 82 DRAINING AND RENEWING THE DUAL WATER SEPA RATING PREFILTER 82 DRAINING AND RENEWING THE SIN...

Page 7: ...ES S A S authorized dealer for the servicing of your engine A list of dealers is available on our website www nannienergy com Read this Manual carefully to learn how to operate and service your engine correctly Failure to do so could result in personal injury or equipment damage This Manual should be considered as a permanent part of the engine and should remain with it even when sold Right hand a...

Page 8: ... the engine i e anyone renting borrowing or buying the engine from you CONTENT UPDATES All the informations and specifications in this Manual are based on the technical data applicable at the time of its publication Changes and updates may be made by Nanni without notice Illustrations are intended as a general guide and may vary from the equipment fitted in the engine in some de tails Some section...

Page 9: ...PROPERLY 13 SAFE ILLUMINATED WORK AREA 13 PROPER LIFTING EQUIPMENT 13 NOISE PROTECTION 13 GENSET OUTPUT GENERATED POWER 13 GUARDS REQUIREMENTS 13 STAYING CLEAR OF ROTATING DRIVELINES 14 PAINT REMOVAL BEFORE HEATING 14 HIGH PRESSURE FUEL SYSTEM OPENING RISK 14 AVOID HIGH PRESSURE FLUIDS 14 SAFE COOLING SYSTEM SERVICE 14 AVOID HEAT NEAR PRESSURIZED FLUID LINES 14 WELDING NEAR ELECTRONIC CONTROL UNIT...

Page 10: ...ation contained on parts and components sourced from suppliers that is not reproduced in this Operator Manual READ SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your genset safety signs Keep safety signs in good condition Be sure new equipment components and repair parts include the current safety signs Replacement safety signs are available from your dealer There ca...

Page 11: ...Refers to important informations and instructions to follow before handling the engine Indicates possible electrical hazards Indicates hot parts entailing substantial risks of burns Indicates an area containing pressurised fluids Indicates hazardous rotating parts Stipulates that no flames or sparks should be created in the vicinity Indicates where to check the coolant level Indicates where to che...

Page 12: ...ntal or recycling center or your dealer for information on the proper way to recycle or dispose of waste UNWANTED ENGINE START Avoid possible injury or death from engine runaway Do not start engine by shorting across the starter motor solenoid terminals posts Engine will start if normal circuitry is bypassed Start engine from operator s seat SAFE MAINTENANCE PRACTICE Understand service procedures ...

Page 13: ...dures in this manual SAFE ILLUMINATED WORK AREA Illuminate your work area adequately and safely Use a portable safety light for working inside the engine room Make sure the bulb is enclosed by a wire cage The hot filament of an accidentally broken bulb can ignite spilled fuel or oil PROPER LIFTING EQUIPMENT Lifting heavy components incorrectly can cause severe injury or equipment damage Use expert...

Page 14: ...sors or any other components between the high pressure fuel pump and nozzles on engines with High Pressure Common Rail HPCR fuel system Only technicians familiar with this type of system can perform repairs Consult your engine representative AVOID HIGH PRESSURE FLUIDS Inspect hydraulic hoses periodically at least once per year for leakage kinking cuts cracks abrasion blisters corrosion exposed wir...

Page 15: ... to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices HANDLE FUEL SAFELY AVOID FIRES Handle fuel with care it is highly flammable Do not refuel the engine while smoking or when near open flame or sparks Always stop engine before refueling Prevent fires by keeping engine room clean of accumulated trash grease and debris Always clean u...

Page 16: ...REVENT BATTERY EXPLOSIONS Keep sparks lighted matches and open flame away from the top of battery Battery gas can explode Never check battery charge by placing a metal object across the posts Use a volt meter or hydrometer Do not charge a frozen battery it may explode Warm up battery to 16 C 60 F before doing it S02 SAFETY WARNING Battery posts terminals and related accessories contain lead and le...

Page 17: ...ALYSIS 25 FUELS 26 DIESEL FUEL 26 SULPHUR CONTENT 26 IMPORTANCE OF LOW SULPHUR DIESEL USE LSD 26 PERMITTED SULPHUR CONTENT IN DIESEL 26 DIESEL WITH A HIGHER SULPHUR CONTENT THAN 500 PPM FOR ENGINES WITH SCR SYSTEMS 27 TEMPERATURE DEPENDENCE OF DIESEL 27 DMX AND DMA DIESEL FUEL 27 HVO 27 BIODIESEL FAME 28 MAINTENANCE INTERVAL 28 STORAGE OF BIODIESEL 28 REDUCTANT FOR SCR 29 32 5 BY WEIGHT OF UREA 29...

Page 18: ...ion used in Scania engines should be antifreeze ethylene glycol and cor rosion inhibitor Only Scania coolant or another product with function ing antifreeze and corrosion protection may be used in Scania engines Products not fulfilling the demands in this section may lead to faults and damage occurring in the cooling system This can lead to the invalidation of Scania s warranty for faults and dama...

Page 19: ...coolant properties with 30 percent by volume of antifreeze and corrosion inhibitor Ice slush starts to form at 16 C 3 F At 30 C 22 F there is a risk of cooling system mal function There is no risk of damage by freezing with a minimum antifreeze and corrosion inhibitor content of 35 percent by volume Example If the temperature is 16 C 3 F there is a risk of dam age by freezing if the percentage of ...

Page 20: ...It should be used in cold countries where there is a risk of freezing in the cooling system Part Volume litres Volume U S Gallons 1 921 955 5 1 3 1 921 956 20 5 3 1 921 957 210 55 1 896 695 1000 264 Scania Ready Mix 35 65 Scania Ready Mix 35 65 is a ready mixed cool ant con taining 35 antifreeze ethylene glycol and corrosion protection and 65 water It should be used in warm countries where there i...

Page 21: ...re required in the cooling sys tem Since there are already 14 litres in the cooling system 4 litres of ethylene glycol must be added to the cooling system 18 14 4 litres S03 FLUIDS ADEQUATE PROTECTION AGAINST CORROSION VOLUME OF ETHYLENE GLYCOL 35 40 45 50 60 COOLING SYSTEM VOLUME LITRES ICE SLUSH FORMS C 21 24 30 38 50 VOLUME OF ETHYLENE GLYCOL LITRES 11 12 14 15 18 30 14 16 18 20 24 40 18 20 23 ...

Page 22: ...7 U S gal lons fill another 1 1 U S gallons of ethylene glycol in the cooling system 4 8 3 7 1 1 U S gallons S03 FLUIDS ADEQUATE PROTECTION AGAINST CORROSION VOLUME OF ETHYLENE GLYCOL 35 40 45 50 60 COOLING SYSTEM VOLUME U S GALLONS ICE SLUSH FORMS F 6 11 22 36 58 VOLUME OF ETHYLENE GLYCOL U S GALLONS 2 9 3 2 3 7 4 4 8 7 9 3 7 4 2 4 8 5 3 6 3 10 6 4 8 5 3 6 1 6 6 7 9 13 2 5 5 6 3 7 1 7 9 9 5 15 9 ...

Page 23: ...n the expansion tank 2 Top up with coolant as necessary S03 FLUIDS CHECKING THE COOLANT S ANTIFREEZE CORROSION PROTECTION Specific tool Description Illustration Refractometer WARNING Avoid skin contact with coolant as this may cause irri tation to the skin Wear protective goggles and gloves when handling coolant IMPORTANT Use only pure fresh water that is free from particles sludge and other impur...

Page 24: ... CJ4 are not recommended Check with your oil supplier that the oil meets these re quirements If the engine is used in areas of the world where engine oil with ACEA or API classification is not available the oil grade must be measured in actual operation In this case contact the nearest Nanni workshop For operation at extremely low outdoor temperatures Consult your nearest Nanni representative on h...

Page 25: ...t be used Certain laboratories offer engine oil analysis The following conditions must remain fulfilled when the oil is changed Viscosity at 100 C 212 F max 20 of original value of the fresh oil TBN in accordance with ASTM D4739 3 5 TBN in accordance with ASTM D4739 TAN in accordance with ASTM D664 Soot according to DIN 51452 3 Fuel in the oil 5 Such analysis measures the oil s TBN Total Base Num ...

Page 26: ...evel Classification 22 20 17 according to ISO 4406 PERMITTED SULPHUR CONTENT IN DIESEL IMPORTANT The operator is responsible for using the correct type of diesel to ensure that local laws are complied with Sulphur content Remark 0 2000 ppm 0 2 Normal oil change interval of up to 500 hours 2000 4000 ppm 0 2 04 The oil change interval must be halved to a maximum of 250 hours 4000 ppm 0 4 Max permitt...

Page 27: ...tact your nearest Nanni representative if you suspect a fault or in case of doubt S03 FLUIDS STORAGE OF BIODIESEL IMPORTANT Biodiesel must not be stored for more than 6 months Biodiesel has a maximum storage life of 6 months from the date of production to the expiry date The fuel is affected by light temperature water etc dur ing storage which affects the fuel characteristics and durability Biodie...

Page 28: ...sel fuel These impurities can pass through the filters and creep into the injection system and cause a total failure of the engine which is not covered by Nanni Industries warranty LONG TERM DIESEL FUEL STORAGE Long term storage of diesel fuel where the diesel comes into contact with water may lead to the growth of micro organisms bacteria and fungus PRESERVATIVE PRODUCTS PRESERVATIVE OIL Always u...

Page 29: ...ed when ordering service and replacement parts Depending of engine identification plate is as follow Or TYP indicates the commercial designation of the engine NR indicates the engine serial number CODE lists various specifications of the engine Example 1 2 3 4 1 Type of engine 2 Engine number 3 Engine code 4 Nanni number ORIGINAL SUPPLIER ENGINE PLATE Example DI13 076M DI Supercharged diesel engin...

Page 30: ...adopt environmentally responsible behaviour Ensure you only use the fuels and oils recommended Using another type of fuel or oil could cause major malfunctions an higher fuel consumption a reduced engine service life and a greater discharge of exhaust gases When draining the oil and changing the oil or fuel filter dispose of the waste in an appropriate container These fluids cause major damage to ...

Page 31: ...ale and delivery of the engines equipment to the ultimate purchaser EUROPEAN UNION EU DECLARATION OF EMISSIONS CONFORMITY The presence of an EU number on the label signifies that the Marine Diesel Engine has been certified with the European Union countries per Directives 97 68 EC as amended by Directive 2004 26 EC The EU engine family is listed on the Emissions Label When installed in accordance w...

Page 32: ...32 S05 COMPONENTS SUMMARY Table des matières S05 COMPONENTS 32 SUMMARY 32 ENGINE MAIN COMPONENTS 33 ENGINE VIEWS N16 CR3 34 ...

Page 33: ...or draining anf filling coolant 1 on each side behind the heat exchanger 8 Oil plug 9 Heat exchanger 1 on each side 10 Fuel filter 11 Hand pump for fuel 12 Oil filter 13 Expansion tank 14 Level glass for checking coolant level 15 Filling coolant 16 Engine number stamped into the cylinder block 17 Engine data plate 18 Fuel manifold bleed nipple 19 Bleed nipple on high pressure pump 20 Charge air co...

Page 34: ...34 S05 COMPONENTS ENGINE VIEWS N16 CR3 ...

Page 35: ...35 NOTES ...

Page 36: ... INTRODUCTION 37 PRODUCT IDENTIFICATION 37 FRONT SIDE 37 PRESENTATION 37 START BUTTON 37 NAVIGATION SCROLL BUTTON HIDE 37 NAVIGATION SCROLL BUTTON 37 STOP BUTTON MUTE 37 ELECTRICAL CONNECTIONS 39 DISPLAYED DATA 40 SAFEGUARD FUNCTION 40 FAULT CODES 41 SYSTEM LAYOUT INCLUDING OPTIONS 48 ...

Page 37: ...ON PRODUCT IDENTIFICATION Each unit bears two identification labels with serial number part number and revision which identifies the unit This information is required when technical sup port is needed FRONT SIDE Panel buttons Command buttons are located on the right side of the unit An Led is coming up when relevant button is ac tivated Start button Navigation scroll button HIDE Navigation scroll ...

Page 38: ...MENSIONS WEIGHT The rugged unit is made of thermoplastic polymer compound PBT impact resistant and flame retarded Item Description Dimensions 119 9 W x 79 6 H x 49 D in mm Weight 0 250 kg Spacing threads 48 5 mm Threads dimension M5 Threads depth 7 7 mm Enclosure PBT PC plastic MOUNTING The SI 3 supports two different mounting methods a RAM mount or a panel mount These two mounting methods are des...

Page 39: ... breakdown Below cutout template dimensions Bracket kneecap ref is RAM B 238U ELECTRICAL CONNECTIONS Once the SI 3 has been fitted in place connections must be made The harness is a plug and play system and is delivered with relevant poka yoke connectors for trou blefree connection to the Engine Control Box To this purpose a cable extension may be required Provision is made for wheelhouse standalo...

Page 40: ...numbers 2 The buzzer will sound 3 This pop up may be removed during 20 sec in press ing the second button on the right side of the unit acti vating the HIDE function 4 The display returns to normal operation and after a delay the pop up fault will come back if fault has not been resolved in the mean time 5 The buzzer may be disabled in pressing the bottom right button MUTE Below an example of faul...

Page 41: ...ltage above normal or shorted high 4 Voltage below normal or shorted low 5 Current below normal or open circuit 6 Current above normal or grounded circuit 7 Mechanical system not responding properly 8 Abnormal frequency pulse width or pending 9 Abnormal update rate 10 Abnormal rate of change 11 Failure mode not identifiable 12 Bad intelligent device or component 13 Out of calibration 14 Special in...

Page 42: ... Coolant Temperature Temperature of liquid found in engine cooling system 111 Engine Coolant Temperature Ratio of volume of liquid found in engine cooling system to total cooling system volume 131 Engine Exhaust Back Pressure Mass flow rate of fresh air entering the engine air intake before any EGR mixer if used 132 Engine Intake Air Mass Flow Rate 156 Engine Injector Timing Rail 1 Pressure The ga...

Page 43: ...ylinder 05 656 Engine Injector Cylinder 06 657 Engine Injector Cylinder 07 658 Engine Injector Cylinder 08 677 Engine Starter Motor Relay Activates the starter 723 Engine Speed 2 Engine Speed 2 788 Transmission Clutch Actuator Identifies the status of the actuator that controls the clutch 968 Engine Idle Increment Switch Switch signal which indicates the position of the idle increment switch 972 A...

Page 44: ...he total volume of diesel exhaust fluid storage container 2791 Engine Exhaust Gas Recirculation 1 EGR1 Valve Control Desired percentage of maximum Exhaust Gas Recirculation EGR valve opening 2797 Engine Injector Group 1 A first collection of fuel injector circuits that are grouped together 2798 Engine Injector Group 2 A second collection of fuel injector circuits that are grouped together 2858 Mac...

Page 45: ...ated farthest downstream in the aftertreatment system in exhaust bank 2 3283 Aftertreatment 2 Exhaust Gas Temperature 2 The reading from the exhaust gas temperature sensor located midstream of the other two temperature sensors in the aftertreatment system in exhaust bank 2 3340 Engine Charge Air Cooler 1 Intake Pressure Pressure of air at intake to 1st or only charge air cooler from multiple first...

Page 46: ...mits for NOx in the exhaust stream have been exceeded due to the diesel exhaust fluid tank being empty 4201 Engine Speed 1 The engine speed as measured by speed sensor 1 4202 Engine Speed 3 The engine speed as measured by speed sensor 3 4225 NOx limits exceeded due to error in the NOx control system On Board Diagnostics has determined that the limits for NOx in the exhaust stream have been exceede...

Page 47: ...9 Engine Throttle Actuator 1 Device used to control the flow of air or air fuel mix to the engine 5421 Engine Turbocharger Wastegate Actuator 1 Device used to control the turbocharger wastegate 5435 Aftertreatment 1 Diesel Exhaust Fluid Pump State State of Aftertreatment 1 Diesel Exhaust Fluid dosing pump 5485 Aftertreatment 1 Diesel Exhaust Fluid Pump Orifice Flow The Exhaust Emission Controller ...

Page 48: ...48 S06 INSTRUMENTATION SYSTEM LAYOUT INCLUDING OPTIONS ...

Page 49: ...51 ENGINE START 52 IGNITION AND CRANKING 52 ENGINE STARTED 52 STARTING WITH BOOSTER BATTERIES 52 ENGINE RELUCTANT TO START 53 IDLING ENGINE 53 NORMAL ENGINE OPERATION 53 BREAK IN 54 POWER TAKE OFF 54 REMOTE CONTROL 54 RUNNING 55 BEHAVIOUR OF THE BOAT 55 DURING OPERATION 55 CRUISING SPEED 55 MANOEUVRING 56 TROLLING VALVE 56 AFTER RUNNING 57 STOPPING THE ENGINE 57 AFTER STOPPING THE ENGINE 57 ANCHOR...

Page 50: ... pump an additional electric fuel feed pump should be installed between the prefilter and the feed pump of the engine RAW WATER SYSTEM The raw water system allows to cool the engine coolant and the exhaust gas Raw water is drawn into the heat exchanger by the engine raw water pump The raw water is drained via the exhaust elbow where it is mixed with exhaust gases The siphon breaker prevents raw wa...

Page 51: ...ck that nobody is in the water near the propeller before starting Never use a start spray or any other equivalent product These products are highly flammable CAUTION Always preheat the engine Never race the engine while it is cold Do not crank the engine continuously for more than 10 seconds at a time Let it cool down for 2 minutes between cranking attempts Failure to follow these guidelines may r...

Page 52: ...y warmed up It is a good practice to operate the engine under a lighter load and at lower speeds than normal for the first few minutes after start up STARTING WITH BOOSTER BATTERIES CAUTION Make sure to use batteries with the same rated voltage as the engine s system voltage On an engine with a two pole electrical system connect the other end of the jumper cable to the negative pole of the booster...

Page 53: ...ine should be idled at slow idle speed Slow idle speed for engine is set at the factory If an engine is left idling for more than 5 minutes stop and restart later Above temperature and pressure on classic gauges NORMAL ENGINE OPERATION Check engine coolant temperature and oil pressure Temperatures and pressures will vary between engines and with changing operating conditions temperatures and lIf c...

Page 54: ... power delivered to the propeller The use of a PTO should always be studied and approved by the R D department of Nanni Industries S A S France Contact your Nanni dealer for more informations REMOTE CONTROL The remote control is an optional extra not in the scope of supply of the engine The remote control installed on the boat can be different than the ones shown in this document NEUTRAL AHEAD AST...

Page 55: ...ERATION Never press the START button when the engine is running The solenoid of the starter motor would push up the cog and make the starter motor to start against the turning flywheel of the engine already in motion This action would destroy the starter motor Check the instruments and warning lamps after starting and regularly when cruising CRUISING SPEED A recommended engine speed is given in th...

Page 56: ...ng and if possible let the boat lose most of its speed 2 Move the control lever to the neutral position and wait a few seconds NEUTRAL 3 Move the control lever into astern Increase the speed ASTERN NEUTRAL TROLLING VALVE The Trolling valve system allows to reduce the rotation speed of the propeller below its speed when the engine is at idle The boat speed is reduced by 30 to 70 CAUTION The Trollin...

Page 57: ...n the key of the main panel counter clockwise All indicators will turn off S07 STARTING RUNNING AFTER STOPPING THE ENGINE CAUTION Even after the engine has stopped some components and fluids will remain hot and under pressure for several minutes As far as possible limit works on the engine immediately after stopping it Allow it to cool down first After the engine has stopped 1 Turn off the main sw...

Page 58: ...d Vegetation and fouling can also obstruct the raw water system and result in damage to the engine by overheating Inspect and clean the boat and the raw water system each time the engine is used Clean if necessary If the boat is removed out of water clean the hull and spray a coat of anti fouling Never paint the anodes Furthermore when the boat is at anchor or in port for an extended period water ...

Page 59: ...THE SACRIFICIAL ANODES 72 CHECKING THE SEA WATER PUMP IMPELLER 72 CHECKING THE SEA WATER PUMP IMPELLER 73 DRAINING THE SEA WATER PUMP IMPELLER 74 REMOVING THE CHARGE AIR COOLER 74 CLEANING THE CHARGE AIR COOLER 75 REMOVING THE HEAT EXCHANGER 76 CLEANING THE HEAT EXCHANGER 77 FITTING THE HEAT EXCHANGER 78 FITTING THE CHARGE AIR COOLER 79 FILLING COOLANT 81 FUEL SYSTEM 82 DRAINING AND RENEWING THE D...

Page 60: ...there is no repair workshop nearby We recommend to have all your works checked by a Nanni authorized workshop Repairs and or adjustment works on the engine by unseasoned marine trained technicians is forbidden for obvious safety reasons Improper works endangers life even not at open sea Operations on valve timing and injection system belong to the exclusive domain of Nanni trained representatives ...

Page 61: ...failures S08 MAINTENANCE MAINTENANCE The maintenance scheddule covers a number of points divided into several sections Lubrication system Air cleaner Cooling system Fuel system Various WARNING Prior to any work onto the engine the starting motor command must be disabled first Alternatively a related electric cable may be removed Should the engine starts unexpectedly there is a serious risk of inju...

Page 62: ...enewing the filter element Renewing the safety cartridge Renewing an air filter with a non rewebable element Lubrication Checking the oil level Changing the oil Cleaning the centrifugal oil cleaner Renewing the oil filter Cooling system Checking the coolant level Checking coolant antifreeze and corrosion protect Checking sacrificial anodes Checking the sea water pump impeller Changing the coolant ...

Page 63: ...as long as possible some basic rules must be followed Changing or cleaning the air filters on a regular basis is a good way to keep debris from causing problems with the intake side of turbochargers A turbocharged engine will definitely need more oil changes than an ordinary atmospheric one as the tur bines axle requires excellent lubrication For this reason oil characteristics must be followed cl...

Page 64: ...ticularly demanding operation such as a dusty envi ronment or if deposits in the centrifugal oil cleaner are thicker than 28 mm 1 1 in Renew the oil filter and clean the centrifugal oil cleaner when changing oil ENVIRONMENT Use a suitable container Used oil must be disposed of as specified in national and international laws and reg ulations 1 Unscrew the oil plug and drain the oil when the engine ...

Page 65: ...side 5 Loosen the rotor nut and unscrew it about 1 5 turns NOTE Take care not to damage the rotor shaft S08 MAINTENANCE 6 If the rotor nut is jammed Turn the rotor upside down and fasten the rotor nut in a vice 7 Use protective jaws so as not to damage the grooves of the rotor nut 8 Turn the rotor 1 5 turns anti clockwise by hand 9 If this does not work Screw two nuts together with an M20 screw 10...

Page 66: ...are undamaged Renew damaged bearings 19 Fold and fit a new paper insert on the inside of the rotor cover as illustrated below 20 Fit the strainer onto the rotor 21 Fit a new O ring to the foot of the centrifugal oil cleaner 22 Refit the rotor cover Ensure that the O ring is not outside the edges but is in the groove 23 Screw the rotor nut back on by hand 24 Check that the shaft is not damaged or l...

Page 67: ...ting need only be carried out if it is suspected that the centrifugal oil cleaner is malfunctioning For example if there are unusually few deposits given the distance driven 1 Run the engine until it reaches normal operating temperature 2 Stop the engine and listen for noise coming from the rotor It should continue rotating for a time even when the engine has stopped 3 Use your hand to feel if the...

Page 68: ...ket IMPORTANT Do not use an adjustable spanner or other open tool as there is a risk of damaging the filter cover 2 Lift out the filter housing cover with filter element The filter housing will drain automatically once the filter has been removed 3 Undo the old filter from the cover by carefully bending it to one side 4 Fit a new O ring on the cover Lubricate the O ring with engine oil 5 Press a n...

Page 69: ...lamp into the element and check from the outside that there are no holes or cracks in the filter paper 4 Assemble the air cleaner 5 Reset the vacuum indicator by pressing in the button Renewing the safety cartridge WARNING Never start the engine without the air filter in position If you do this you risk personal injury and severe engine damage IMPORTANT When you renew the safety cartridge take gre...

Page 70: ...he air cleaner 7 Ensure that the O ring is not outside the edges 8 Reset the vacuum indicator by pressing in the button marked in the illustration COOLING SYSTEM WARNING Ethylene glycol can be fatal if ingested and can cause skin irritation and eye damage NOTE The coolant should be changed when the cooling system is cleaned every 6 000 hours or at least every 5 years See the section Changing the c...

Page 71: ...pansion tank 2 Top up with coolant as necessary S08 MAINTENANCE CHECKING THE COOLANT ANTI FREEZE AND CORROSION PROTECTION Tools required Designation Illustration Refractometer IMPORTANT Use only pure fresh water that is free from particles sludge and other impurities 1 Pour a small amount of coolant into a container and check that the coolant is pure and clear 2 Change the coolant if it is contami...

Page 72: ...not heavily splintered or damaged S08 MAINTENANCE Renewing the sea water pump impeller Special tool required Number Designation Illustration 2 443 680 Puller Note If the impeller must be renewed frequently the cleaning of the sea water needs to be improved There should be a spare impeller on board The impeller can be deformed during extended periods of inactivity Renew the impel ler before startin...

Page 73: ...ve gloves as coolant can cause irritation if it comes in contact with the skin Hot coolant can also cause scalding ENVIRONMENT Use a suitable container Used coolant must be dis posed of as specified in national and international laws and regulations 1 Open the expansion tank cap 2 Place the hose from the coolant pump in an empty container 3 Connect the pump to the draining nipple in the cylin der ...

Page 74: ...ections to prevent dirt ingress into the en gine REMOVING THE CHARGE AIR COOLER When the charge air cooler core needs cleaning the charge air cooler must be removed if there is no space behind it to take out the core 1 Make sure that the cooling system is completely drained as described in the previous section 2 Unscrew and remove the catwalk protective plate and the protective casing 3 On the lef...

Page 75: ...e charge air pipe during removal 8 Remove the screws securing the charge air cooler 9 Lift out the charge air cooler CLEANING THE CHARGE AIR COOLER The charge air cooler must be removed if there is no space behind it to take out the cooler cores See previ ous section 1 Remove the sea water pipes to and from the charge air cooler Remove flanges and charge air pipe from the charge air cooler Remove ...

Page 76: ...oler Tighten the M8 screws on the cover to 15 Nm 11 lb ft Legend 1 Cover 2 O rings 3 Spacer 4 Charge air cooler housing 5 Cooler core S08 MAINTENANCE REMOVING THE HEAT EXCHANGER When the heat exchanger core needs cleaning the heat exchanger must be removed WARNING Use protective gloves as coolant can cause irritation if it comes in contact with the skin Hot coolant can also cause scalding 1 Make s...

Page 77: ...covers Mark the covers so that you can put them back on the correct side 2 Press in the cooler core 5 slightly on one side and pull it out from the other side 3 Clean the cooler core on the outside with paraffin based engine detergent Remove any internal deposits using a round rod Renew the cooler core if it is dam aged IMPORTANT Do not use caustic soda as this could damage the alu minium 4 Renew ...

Page 78: ...torque 50 Nm 37 lb ft 3 Lubricate and fit the coolant pipe from the heat ex changer Angle the pipe from the thermostat housing inwards and push it onto the connection 4 Fit the coolant pipe with the thermostat housing cover 5 Fit the sea water pipe between the charge air cooler and heat exchanger 6 If the engine has a water cooled exhaust pipe bend Fit the sea water pipe between the heat exchanger...

Page 79: ...it the sea water pipe from the sea water pump first to the charge air cooler the inner pipe and then from the charge air cooler to the heat exchanger the outer pipe 5 Fit the charge air pipe and the hose clamps 6 Fit the crankcase ventilation hose 7 Fit the catwalk Loosely fit the protective plate to the charge air pipe Tighten the screws later Fit the protective casing Tighten the screws later Fi...

Page 80: ... for approximately 20 30 min utes Remember to switch on the cab heating system if one is installed 5 Drain the cooling system 6 Fill the cooling system with clean hot water and run the engine for about 20 30 minutes 7 Repeat steps 3 6 if the cooling system is not clean 8 Drain the water from the cooling system 9 If necessary clean the expansion tank by detaching all hoses and rinsing and cleaning ...

Page 81: ...p 2 Connect the coolant pump to the filler nipple in the cylinder block 3 Connect the pump s two cable terminals to the bat tery s negative and positive terminal Make sure that the filling starts If the filling does not start Change the po sition of the cable terminals 4 Start the engine and run it at idling for 15 minutes Above filler nipple in the cylinder block behind the heat exchanger IMPORTA...

Page 82: ...he components with a lint free cloth Checking the fuel level Check the fuel level and fill with fuel as necessary Note If the fuel tank has been run dry or if the engine has not been used for a long time bleed the fuel system See the section Venting the fuel system DRAINING AND RENEWING THE DUAL WATER SEPARATING PREFILTER IMPORTANT The sensor cable is sensitive Handle it carefully ENVIRONMENT Use ...

Page 83: ...e sure that the drain tap is fully closed 8 Lubricate the O ring on the filter with engine oil 9 Fill the width of the filter with clean fuel 10 Screw the filter into position until the O ring rests against the filter head Tighten the filter another 1 2 to 3 4 turn by hand 11 Open the shut off cock on the fuel pipe and check that the fuel system is sealed 12 Screw the sensor cable in the contact h...

Page 84: ...and S08 MAINTENANCE RENEWING THE REVERSIBLE WATER SEPARATING PREFILTER During operation the arrow on the rotary control should point towards the filter being used ENVIRONMENT Use a suitable container The fuel collected must be dis posed of as specified in national and international laws and regulations 1 Switch off the filter that needs renewing During re newal the arrow on the rotary control poin...

Page 85: ...clear plastic hose to the bleed nipple sitting above filter A Place the other end in a container with a capacity of at least 3 8 litres 1 US gallon 4 Open the bleed nipple on side A The remaining pres sure is released 5 Clean the exterior of the filter with a cloth 6 Unscrew the filter 7 Apply O ring grease part number 2 002 537 to the gasket on the new filter 8 Screw the filter into place by hand...

Page 86: ... as specified in national and international laws and regulations 1 Screw up the hand pump handle 1 2 Attach a clear plastic hose to the bleed nipple on the fuel filter 2 Let the plastic hose drop into a container that holds at least 5 litres 1 3 US gallons 3 Open the bleed nipple on the fuel filter 4 Pump with the hand pump until fuel comes out 5 Close the bleed nipple on the fuel filter 6 Attach ...

Page 87: ...lose the ventilating valve on the high pressure pump Remove the hose and suction tool 5 Start the engine and check that no leaks BLEEDING THE FUEL SYSTEM USING A HAND PUMP ON 16 LITRES MARINE ENGINE XPI ENVIRONMENT Use a suitable container The fuel collected must be dis posed of as specified in national and international laws and regulations 1 Turn the rotary control so that it is pointing towards...

Page 88: ...high pressure pump Tightening torque 9 Nm Screw down the hand pump handle 9 Start the engine The engine should be easy to start MISCELLANEOUS CHECKING THE DRIVE BELT IMPORTANT 1 Check the drive belt thoroughly particularly at the idler rollers 2 Check the drive belt for cracks Renew the drive belt if deep cracks have formed Note Small and shallow cracks are normal and form after only a few hours o...

Page 89: ...AKAGE IMPORTANT If serious leakage occurs contact your nearest Nanni representative 1 Start the engine 2 Check for leaks in the lubrication intake cooling fuel or exhaust system 3 Tighten or renew leaking connections Check the over flow holes which show whether the O rings between the cylinder liners and crankcase are leaking ...

Page 90: ...place which is every 2 000 operational hours S08 MAINTENANCE The reference information UP TDC DOWN TDC and the angle indications listed in the table below are engraved on the flywheel Depending on the engine installation and type of flywheel housing this information is visible in one of the windows either furthest up or furthest down on the flywheel See illustration below Upper and lower window to...

Page 91: ...m the back of the engine During a valve transition the exhaust valve the long arm is closing at the same time as the intake valve is opening The UP TDC engraving on the flywheel is now visible in the window furthest up on the flywheel The DOWN TDC engraving is visible in the lower window 5 Read the table on the previous page to see which valve to adjust 6 Stick the feeler gauge under the pressure ...

Page 92: ... 310 M22 580 428 M24 730 538 Flange screws with hexagonal head and hexagonal flange nuts THREAD TIGHTENING TORQUE Nm Lb ft M5 6 7 5 M6 10 2 8 M8 26 19 M10 50 37 M12 92 38 M14 149 110 M16 1184 136 S08 MAINTENANCE Hose clamps Specifications in the tables show tightening torque when tightening by hand A WIDTH mm TIGHTENING TORQUE Nm LB FT 7 5 9 1 5 1 12 5 4 Tightening torque for new unfitted hose cla...

Page 93: ...le des matières S09 STORAGE 93 SUMMARY 93 LONG TERM STORAGE 94 PREPARATIONS FOR STORAGE 94 LONG TERM STORAGE PROCEDURE 94 PRESERVATIVE PRODUCTS 95 PRESERVATIVE COOLANT 95 PRESERVATIVE FUEL 95 RESTARTING THE ENGINE 95 BATTERY 95 ...

Page 94: ...ansmission oil 2 Change the engine oil filter 3 Change the fuel filter and prefilter 4 Run the engine to normal operating temperature 5 Stop the engine and take the boat out of water 6 Drain and clean all components of the seawater system Protect the components against corrosion 7 Remove the impeller from the seawater pump if fitted Store it in a cool and dry place Indicate by any means that the i...

Page 95: ...TING THE ENGINE 1 Perform external cleaning of the engine and control its condition 2 Drain and change the engine and transmission oil 3 Change oil filters 4 Drain the coolant from the seawater system 5 Check the condition of the raw water pump impeller Change it if needed Install the impeller 6 Remove cloth and tape from openings Install the air filter 7 Close Tighten all plugs and drain cocks 8 ...

Page 96: ... 8 9 The starter motor is not turning or turn slowly 8 9 The starter motor turns but the engine does not start 1 2 3 4 5 6 7 The engine does not reach its rated speed at wide open throttle 2 3 4 5 6 7 12 14 15 16 17 26 28 The engine operate unevenly 1 2 3 4 5 6 7 14 15 16 17 18 19 20 24 28 The engine vibrates a lot 16 27 Black exhaust smoke 4 5 14 15 16 19 20 28 29 White exhaust smoke 4 5 23 25 Hi...

Page 97: ...Stop control pulled out 14 Too much load on board 15 Fouling on underwater hull drive or propeller 16 Defective incorrect propeller 17 Faulty operation of control lever control cables 18 Loosen or damaged belt 19 Incorrect coolant Low coolant level Coolant leaks 20 Cooling system does not operate correctly 21 Faulty thermostat 22 Sea cock valve closed Raw water filter clogged 23 Lube oil burns Exc...

Page 98: ... driven valve train Système d injection Fuel system Injection Rampe Commune XPI Common Rail Injection XPI Ordre d allumage Firing order 1 5 4 2 6 3 7 8 Sens de rotation vue côté volant moteur Rotational direction view flywheel side Antihoraire Counter clockwise Cylindrée Displacement liltres 16 4 in 1000 8 Alésage Bore mm 130 in 5 1 Course Stroke mm 154 in 6 1 Régime de ralenti Idling speed tr min...

Page 99: ...5 87 133 167 gal US h 1 6 8 2 14 8 17 2 23 35 1 44 1 Consommation de carburant à pleine charge Fuel consumption at full load l h 167 gal US h 44 1 Débit volumique de carburant à pleine charge Total volumetric fuel flow at full load l h 300 gal US h 79 3 Restriction maximale d admission de carburant Maximum fuel inlet restriction kPa 30 psi 4 4 Résistance maxi au passage du carburant Maximum permit...

Page 100: ...Exhaust gas flow kg min 60 Contre pression maxi admissible dans le circuit d échappement Permitted back pressure in the exhaust line bar 0 1 inH O 40 15 Température d échappement maxi Maximum exhaust temperature C 411 F 771 8 SYSTEME D ADMISSION AIR INTAKE SYSTEM Consommation d air du moteur à 25 C Engine air consumption at 25 C kg min 57 3 Température d air d admission maxi admissible Maximum all...

Page 101: ...SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 1660 lbs 3659 7 CONSEILS D INSTALLATION INSTALLATION TIPS Diamètre tuyau alimentation carburant Fuel line supply diameter mm 16 in 0 63 Diamètre tuyau retour carburant Fuel line return diameter mm 12 in 0 47 Diamètre Tuyau eau de mer Sea water line diameter mm Aspiration 63 Sortie 2 x 51 in Intake 2 48 Outlet 2 x 2 01 Diamètre l...

Page 102: ...r driven valve train Système d injection Fuel system Injection Rampe Commune XPI Common Rail Injection XPI Ordre d allumage Firing order 1 5 4 2 6 3 7 8 Sens de rotation vue côté volant moteur Rotational direction view flywheel side Antihoraire Counter clockwise Cylindrée Displacement liltres 16 4 in 1000 8 Alésage Bore mm 130 in 5 1 Course Stroke mm 154 in 6 1 Régime de ralenti Idling speed tr mi...

Page 103: ... 72 96 127 187 gal US h 1 9 9 2 16 4 19 25 4 33 5 49 4 Consommation de carburant à pleine charge Fuel consumption at full load l h 187 gal US h 49 4 Débit volumique de carburant à pleine charge Total volumetric fuel flow at full load l h 300 gal US h 79 3 Restriction maximale d admission de carburant Maximum fuel inlet restriction kPa 30 psi 4 4 Résistance maxi au passage du carburant Maximum perm...

Page 104: ...t Exhaust gas flow kg min 63 Contre pression maxi admissible dans le circuit d échappement Permitted back pressure in the exhaust line bar 0 1 inH O 40 15 Température d échappement maxi Maximum exhaust temperature C 434 F 813 2 SYSTEME D ADMISSION AIR INTAKE SYSTEM Consommation d air du moteur à 25 C Engine air consumption at 25 C kg min 60 3 Température d air d admission maxi admissible Maximum a...

Page 105: ...smission kg 1660 lbs 3659 7 CONSEILS D INSTALLATION INSTALLATION TIPS Diamètre tuyau alimentation carburant Fuel line supply diameter mm 16 in 0 63 Diamètre tuyau retour carburant Fuel line return diameter mm 12 in 0 47 Diamètre Tuyau eau de mer Sea water line diameter mm 63 in 2 48 Diamètre ligne d échappement Exhaust line diameter en accord avec l installation voir contrepression according to th...

Page 106: ...r driven valve train Système d injection Fuel system Injection Rampe Commune XPI Common Rail Injection XPI Ordre d allumage Firing order 1 5 4 2 6 3 7 8 Sens de rotation vue côté volant moteur Rotational direction view flywheel side Antihoraire Counter clockwise Cylindrée Displacement liltres 16 4 in 1000 8 Alésage Bore mm 130 in 5 1 Course Stroke mm 154 in 6 1 Régime de ralenti Idling speed tr mi...

Page 107: ...8 79 105 139 207 gal US h 2 1 10 18 20 9 27 7 36 7 54 7 Consommation de carburant à pleine charge Fuel consumption at full load l h 207 gal US h 54 7 Débit volumique de carburant à pleine charge Total volumetric fuel flow at full load l h 300 gal US h 79 3 Restriction maximale d admission de carburant Maximum fuel inlet restriction kPa 30 psi 4 4 Résistance maxi au passage du carburant Maximum per...

Page 108: ...t Exhaust gas flow kg min 66 Contre pression maxi admissible dans le circuit d échappement Permitted back pressure in the exhaust line bar 0 1 inH O 40 15 Température d échappement maxi Maximum exhaust temperature C 459 F 858 2 SYSTEME D ADMISSION AIR INTAKE SYSTEM Consommation d air du moteur à 25 C Engine air consumption at 25 C kg min 62 6 Température d air d admission maxi admissible Maximum a...

Page 109: ...9 7 CONSEILS D INSTALLATION INSTALLATION TIPS Diamètre tuyau alimentation carburant Fuel line supply diameter mm 16 in 0 63 Diamètre tuyau retour carburant Fuel line return diameter mm 12 in 0 47 Diamètre Tuyau eau de mer Sea water line diameter mm Aspiration 63 Sortie 2 x 51 in Intake 2 48 Outlet 2 x 2 01 Diamètre ligne d échappement Exhaust line diameter En accord avec l installation voir contre...

Page 110: ...r driven valve train Système d injection Fuel system Injection Rampe Commune XPI Common Rail Injection XPI Ordre d allumage Firing order 1 5 4 2 6 3 7 8 Sens de rotation vue côté volant moteur Rotational direction view flywheel side Antihoraire Counter clockwise Cylindrée Displacement liltres 16 4 in 1000 8 Alésage Bore mm 130 in 5 1 Course Stroke mm 154 in 6 1 Régime de ralenti Idling speed tr mi...

Page 111: ... 95 110 145 219 gal US h 2 1 10 6 18 8 25 1 29 1 38 3 57 9 Consommation de carburant à pleine charge Fuel consumption at full load l h 219 gal US h 57 9 Débit volumique de carburant à pleine charge Total volumetric fuel flow at full load l h 300 gal US h 79 3 Restriction maximale d admission de carburant Maximum fuel inlet restriction kPa 30 psi 4 4 Résistance maxi au passage du carburant Maximum ...

Page 112: ...t Exhaust gas flow kg min 67 Contre pression maxi admissible dans le circuit d échappement Permitted back pressure in the exhaust line bar 0 1 inH O 40 15 Température d échappement maxi Maximum exhaust temperature C 474 F 894 2 SYSTEME D ADMISSION AIR INTAKE SYSTEM Consommation d air du moteur à 25 C Engine air consumption at 25 C kg min 63 8 Température d air d admission maxi admissible Maximum a...

Page 113: ...ids sans transmission Weight without transmission kg 1660 lbs 3659 7 CONSEILS D INSTALLATION INSTALLATION TIPS Diamètre tuyau alimentation carburant Fuel line supply diameter mm 16 in 0 63 Diamètre tuyau retour carburant Fuel line return diameter mm 12 in 0 47 Diamètre Tuyau eau de mer Sea water line diameter mm Aspiration 63 Sortie 2 x 51 in Intake 2 48 Outlet 2 x 2 01 Diamètre ligne d échappemen...

Page 114: ...r driven valve train Système d injection Fuel system Injection Rampe Commune XPI Common Rail Injection XPI Ordre d allumage Firing order 1 5 4 2 6 3 7 8 Sens de rotation vue côté volant moteur Rotational direction view flywheel side Antihoraire Counter clockwise Cylindrée Displacement liltres 16 4 in 1000 8 Alésage Bore mm 130 in 5 1 Course Stroke mm 154 in 6 1 Régime de ralenti Idling speed tr mi...

Page 115: ... 99 114 151 230 gal US h 2 1 11 1 19 6 26 2 30 1 39 9 60 7 Consommation de carburant à pleine charge Fuel consumption at full load l h 230 gal US h 60 7 Débit volumique de carburant à pleine charge Total volumetric fuel flow at full load l h 300 gal US h 79 3 Restriction maximale d admission de carburant Maximum fuel inlet restriction kPa 30 psi 4 4 Résistance maxi au passage du carburant Maximum ...

Page 116: ...ent Exhaust gas flow kg min 68 Contre pression maxi admissible dans le circuit d échappement Permitted back pressure in the exhaust line bar 0 1 inH O 40 15 Température d échappement maxi Maximum exhaust temperature C 490 F 914 SYSTEME D ADMISSION AIR INTAKE SYSTEM Consommation d air du moteur à 25 C Engine air consumption at 25 C kg min 65 Température d air d admission maxi admissible Maximum all...

Page 117: ...ids sans transmission Weight without transmission kg 1660 lbs 3659 7 CONSEILS D INSTALLATION INSTALLATION TIPS Diamètre tuyau alimentation carburant Fuel line supply diameter mm 16 in 0 63 Diamètre tuyau retour carburant Fuel line return diameter mm 12 in 0 47 Diamètre Tuyau eau de mer Sea water line diameter mm Aspiration 63 Sortie 2 x 51 in Intake 2 48 Outlet 2 x 2 01 Diamètre ligne d échappemen...

Page 118: ......

Page 119: ...Nanni Industries S A S 11 Avenue Mariotte 33260 La Teste France Tel 33 0 5 56 22 30 60 Fax 33 0 5 56 22 30 79 www nannienergy com ...

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