Nanni T4.205 Operator'S Manual Download

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ONTENTS

Introduction ............................. 1

About this manual .........................2

Safety ........................................ 3

Emergency kit ...............................3

Safety alert symbols ......................3

Safety icons...................................4

Safety precautions ........................5

Overview .................................. 9

About the engine ...........................9

Warranty ......................................13

Propeller selection ......................13

Behaviour of the boat ..................14

Engine main components ...........15

Instruments panel ................. 17

Standard panel ............................17

Instrumentation ...........................18

Operation ............................... 23

Before starting .............................23

Starting the engine ......................24

During operation .........................26

Stopping the engine ....................28

Maintenance .......................... 32

Service schedule .........................33

General inspection ......................35

Fuel system .................................37

Lubrication system ......................40

Cooling system ...........................43

Raw water system.......................47

Electrical system .........................51

Battery .........................................52

Corrosion protection ...................54

Long term storage .......................57

Troubleshooting .................... 59

Technical data ....................... 61

Summary of Contents for T4.205

Page 1: ...Nanni marine engine Operator s manual Engines T4 205 T4 230 T4 270 ...

Page 2: ...English You can download a copy of this manual in English on nannidiesel com Français Vous pouvez télécharger ce manuel en Français sur notre site Web à l adresse www nannidiesel com ...

Page 3: ...ine main components 15 Instruments panel 17 Standard panel 17 Instrumentation 18 Operation 23 Before starting 23 Starting the engine 24 During operation 26 Stopping the engine 28 Maintenance 32 Service schedule 33 General inspection 35 Fuel system 37 Lubrication system 40 Cooling system 43 Raw water system 47 Electrical system 51 Battery 52 Corrosion protection 54 Long term storage 57 Troubleshoot...

Page 4: ...ith precise specifications and strict production methods Before operating the engine make sure that this manual is applicable to the engine Refer to the Identification plate if you are not sure about the engine model designation If you don t have the correct manual please contact your Nanni authorized Dealer Correct installation of the engine on your boat is of the greatest importance for safe nav...

Page 5: ...ument the following symbols are used to ease the reading Indicates that the text is conti nued on the following page Indicates the end of a section Content and updates All the informations and specifica tions 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 ...

Page 6: ...can order an emergency kit from any Nanni authorized dealer The engine emergency kit contains several components to carry out simple repair in the event of a fault Always have an complete emer gency kit onboard and necessary tools to carry out any repairs Safety alert symbols General rules of safety precautions to follow are indicated in this Ma nual They are indicated as follows I DANGER Indicate...

Page 7: ... to follow before handling the engine Indicates possible electrical hazards This icon indicates a risk of fire Indicates hot parts entailing substantial risks of burns Indicates an area containing pressurised fluids Stipulates that no flames or sparks should be created in the vicinity Indicates hazardous rotating parts Indicates the de aeration orifice s air bleed Indicates where to check the cool...

Page 8: ... gets very hot the exhaust system tur bocompressor if equipped starter oil sump oil coolant in the hoses and pipes are hot and can burn Fluids ejected under pressure can cause serious injury Release all the pressure in the circuits before removing the caps Never open the oil circuit and coolant caps when the engine is operational and or hot Never start or run the engine when the oil fill and coola...

Page 9: ...Ensure you always have an appropriate working fire extinguisher to hand Hazardous Voltage Electrical Shock Electrocution is possible whenever electricity is present Hazardous voltage can cause severe injury or death Operate the engine only when all guards and electrical en closures are in place Open the main circuit breakers of all power sources before servi cing the equipment Configure the instal...

Page 10: ...n which could ignite or explode on contact with an electrical arc or a flame Switch off all electrical appliances in the vicinity when you are working on the batteries Ventilate correctly storage batteries compartment Avoid touching the battery terminals with metal tools so that no sparks are created which could cause an explosion Remove the rings bracelets and necklaces before handing the batteri...

Page 11: ...ng for possible leaks Water ingress The engine should be protected against from water ingress by any means Water ingress leads to complete engine failure This is not cover under any warranty terms Water can enter the engine after filling the exhaust system Correct installation of the engine on your boat is of the greatest impor tance for safe navigation and pro tection of the environment The first...

Page 12: ...50 hours of operation Do not race the engine while it is cold Do not operate it at full load except for short periods Never run the engine at constant engine speed for long periods during the break in period Check the oil and coolant level frequently during the running in period The oil consumption can be more important during the running in period Engine installation The installation must be carr...

Page 13: ...e operation of the remote control Power Take Off Some engines can be fit with a Power Take Off system This sys tem allows to power accessories like bilge pump watermaker etc NOTICE Any mechanical power taken from the engine from a PTO reduces the 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 yo...

Page 14: ...l has a lower BTU heat content rating Check the grade of fuel being used before troubleshooting for low power com plaints in cold weather operation In all cases fuel quality and fuel sulfur content must comply with all existing emissions regulation for the area in which the engine operates Oil viscosity Use seasonal grade viscosity engine oil based on the expected air temperature range between oil...

Page 15: ...nstructions stated in the relevant manuals should be follow by the user Nanni s responsibility for the engine specification being in accordance with the certification will be invali date if one or several of this condi tions are not followed Environmental responsibility Nanni designs its engines to have minimum environmental impact This objective however can only be achieved with your full coopera...

Page 16: ...itional equipment etc ARE FORBIDDEN WITH OUT WRITTEN AUTHORIZATION FROM NANNI INDUSTRIES S A S Any modification will void the War ranty Damage caused by failure to follow operation instructions or incorrect operation is also not cove red by the warranty Propeller selection The propeller is a critical compo nent of the propulsion system It converts the engine power in thrust To be efficient the pro...

Page 17: ...istribution passengers equip ments etc inside the boat has an impact on the behaviour of the boat when cruising Depending the position of the load the behaviour of the boat may change particularly in the case of a planning hull The condition of the hull and the propeller is also a critical factor A dirty and or damaged hull will mo dify the behaviour of the boat and therefore the engine performanc...

Page 18: ... Alternator 2 Alternator belt 3 Starter 4 Fuses box 5 Air filter 6 Fuel filter 7 Fuel cooler 8 High pressure Injection pump 9 Heat exchanger 10 Heat exchanger filler cap 11 Coolant pump 12 Turbocompressor 13 Coolant drain plug 14 Raw water pump 15 Oil filter 16 Oil filler port 17 Oil gauge 18 Water cooled exhaust elbow 19 ECU 20 EDU 21 Intercooler 15 ...

Page 19: ...T4 205 T4 230 T4 270 1 2 3 15 9 6 7 19 5 8 4 10 11 12 20 13 21 14 16 17 18 13 16 ...

Page 20: ...nts can be installed on panel or separate ly on the dashboard 17 INSTRUMENTATION 5 Tachometer LCD display The analog tachometer displays the engine speed Multiply the indicated value by 1000 to get the revolutions per minute of the engine The functions of the LCD and alarms are described in the follow ing pages 125 HRS THR ENGINE HRS MODE Alternator charge indicator Shows the voltage at the altern...

Page 21: ...nel To start the engine us ing the additional panel the key of the main panel should be switched to IGNITION position Engine oil pressure indicator 0 2 8 6 4 OIL BAR NOTICE This indicator does not show the engine oil level This indicator shows the oil pressure in bar and psi If the oil pressure in the lubrication circuit is too low the acoustic alarm sounds and the corresponding warning lamp comes...

Page 22: ...t in extreme emer gencies and check the coolant level the belt condition the raw water filter condition and that the sea cock is open Operating the engine while the coolant temperature is too high can lead to severe engine damage Do not operate the engine if the problem persists and contact a Nanni workshop as soon as possible Fuel level indicator FUEL Indicates the approximate amount of fuel rema...

Page 23: ...e operating ranges are avail able 1 TRIM RANGE The trim range is used to adjust the boat trim at all engine rpm speed from idle to max rpm at wide open throttle 2 BEACH RANGE The beach range is used to raise the drive for running at reduced speed in shallow water or when water depth is uncertain CAUTION The max engine speed allowed when the drive is in the beach range is 1000 rpm 3 LIFT RANGE TOWI...

Page 24: ...unctions may not be available for your display It is not recom mended to change the settings in edit mode Main menu Setting Edit mode Engine rpm Reset fuel used Fuel setup Trim position Trip data Cal speedo Hourmeter Contrast Cal Trim Current trip time Lighting Max speed Immediate fuel con sumption Display setup Remaining fuel Data sources Alternator voltage Pop up alerts Clock Alterts setup Cours...

Page 25: ...22 Note ...

Page 26: ...ary 2 Start the compartment fan if fitted for at least five minutes Otherwise open the hold 3 Check that there is sufficient fuel 4 Move the control lever to the neutral position 5 Open fuel cock prime the sys tem if necessary 6 Check the engine and trans mission oil level and fill with the recommended oil if necessary 7 Check the coolant level top up if necessary 8 Check the control cables grease...

Page 27: ...s NOTICE When starting the engine for the first time let it run at idle for several minutes and check for leaks or malfunction Starting using booster batteries CAUTION Make sure to use batteries with the same rated voltage as the engine s system voltage 1 Connect the jumper cable to the positive pole of the flat battery then to the positive pole of the booster battery 2 Connect the jumper cable to...

Page 28: ...xhaust outlet at the hull If the water does not flow stop the engine and check the raw water system Panel without key 1 Switch the key of the main panel to ignition if equipped 2 Move the control lever to the neutral position 3 Press the ON STOP button All the warning lamps come on and the acoustic alarm sounds After a few seconds only the ENGINE OIL PRESSURE and BATTERY CHARGE LAMPS remain lit 4 ...

Page 29: ...t a Nanni workshop as soon as pos sible Cruising speed A recommended engine speed is given in the chapter TECHNICAL DATA to help you to set your cruis ing speed Always consider sailing conditions and load of the boat to set the cruising speed Operating the engine at wide open throttle should be avoided since it is both uncomfortable and uneco nomical Note that operating the engine at a too low rpm...

Page 30: ...se extreme caution when cruising in shallow water or in areas likely to contain submerged objects that can hit the propeller the drive the hull etc After hitting a submerged object immediately switch off the engine and check the condition of the transmission the propeller shaft the drive and the tie bar Stern Drive version only and the hull CAUTION A damaged tie bar may affect steering characteris...

Page 31: ...ime in the beach or in the lift range The drive is protected against corrosion by anodes and a special paintwork Make sure not to damage the anode and check their condition regularly The trim system is operated using the trim control located at the control position It is generally inte grated to the control station NOTICE The model of control station and trim control can vary according the boat In...

Page 32: ... clockwise All indicators turn off CAUTION Even after the engine has stopped some components and fluids remain hot and pressuri sed for several minutes As far as possible limit work on the en gine immediately after stopping it when it is hot After the engine has stopped 1 Switch off the main switch 2 Close the sea cock and the fuel cock 3 Inspect the engine compart ment and check for any leaks CAU...

Page 33: ...ecessary to drain regularly the wa terlock when the boat is at anchor Storage If the boat is being left in the water while not in use for few weeks the engine must be controlled and run few minutes every 10 days If the boat will not be used for more than 2 months special set of operations must be performed on the engine and the transmission Refer to the chapter LONG TERM STORAGE To prevent damages...

Page 34: ...Note 31 ...

Page 35: ...wever some regular checks particularly those made each time the engine is used can only be carried out by the user Few other operations are explained further on so that you can work on the engine in an emergency or if there is no repair centre nearby We recommend to have all your works checked by a Nanni author ized workshop Independent repair and adjust ment work on the engine beyond a limited sc...

Page 36: ...ary Check the raw water filter and clean as necessary Drain water from the fuel prefilter Check the condition of the battery Check the warning lamps of the instrument panel Control and adjust general water tightness Check the stuffing box condition EVERY 100 OPERATING HOURS AT LEAST EVERY YEAR Clean the air filter Change if needed Change the fuel filter Check the condition and the tension of the b...

Page 37: ...ge the thermostat of the heat exchanger Change the heat exchanger filler plug Drain and change the coolant Clean the coolant system Check and clean the heat exchanger tube stack Change the O ring Check and clean the air cooler tube stack Change the O ring Check and clean the transmission oil cooler tube stack Check the fuel injection nozzles Change if needed Check cold valve clearance Check and cl...

Page 38: ... tension of the cable if necessary If any defect appears rust crack etc the control cable must be changed Stuffing box I DANGER A stuffing box lubricated with raw water taken from the engine cooling system must never be installed on a Sail boat or when the exhaust elbow is below the waterline A separated water supply or a stuffing box lubricat ed by grease must be used on all Sail boat or when the...

Page 39: ...hese operations when the engine is stopped and cold Make sure that no dust or dirt enter the intake manifold The air filter reduces the level of noise made by the air intake and prevent particles from penetrating the intake manifold The reliability and the perform ances of the engine depend among other things on the quantity and the temperature of the intake air To check the air filter 1 Remove th...

Page 40: ...e fuel feed pump and is injected into the combustion chamber by the injection pump A fuel filter is placed between the feed pump and the injection pump The injection pump delivers a larger amount of fuel than required for combustion The fuel that is not burned is re injected into the tank through an over flow pipe I CAUTION The injection pump is an extre mely precise unit Water entry in the fuel s...

Page 41: ...n the fuel injection system If the boat is not used for an ex tended period fill the tank to the maximum level Fuel prefilter The fuel prefilter is an optional ex tra not in the scope of supply of the engine The model of prefilter can vary according the boat NOTICE Drain the water in the prefilter several hours after the engine has been stopped 1 Close the fuel cock on the fuel tank 2 Place a cont...

Page 42: ... and bleed the air in the fuel system Air bleeding Bleeding the air in the fuel system is necessary After a maintenance operation on the fuel system If the fuel tank has been emp tied The engine has not been started for a long time To bleed the fuel system IF IT IS NOT FITTED with an electric pump 1 Fill totally the fuel tank Open the fuel cock 2 Loose the venting screw Use rags around the venting...

Page 43: ...stem I CAUTION Never over fill the engine oil crankcase NOTICE With a new or recon ditioned engine oil and oil filters must be changed after 20 hours of operation Use oil grades quality indicated in the chapter TECHNI CAL DATA Warranty claims may be rejected if unsuitable oil grade has been used The viscosity may be adapted de pending the climatic conditions Oil level Adding engine oil Check the e...

Page 44: ... and replace the cap on the drain pipe Changing the oil filter Change the oil filter each time the engine oil is drained 1 Remove the oil filter with a filter wrench Turn the filter counter clockwise Remove the gasket 2 Clean the mating surface in order to prevent impurities from entering the engine 3 Apply a film of oil on the new gasket Screw the new filter by hand with the new gasket When the g...

Page 45: ...c transmission fluid Replace the fill cap and dipstick Stern Drive gear lube CAUTION Damage to the Stern drive unit may occur due to lack of lubrication If any water is visible at the bottom of the gear lube monitor or if the gear lube appears disco lored stop the engine except in case of emergency and contact a Nanni workshop It may indi cate a water leak in the Stern drive unit Check the gear lu...

Page 46: ... exchanger in which the coolant is cooled by heat exchange with raw water taken from a sea cock A Keel Cooling system can also be used to cool the coolant instead A thermostat maintains the coolant at a proper and constant operating temperature With thermostat con trol the coolant only enter the heat exchanger when the engine reach a certain temperature I CAUTION Operating the engine without coola...

Page 47: ...tended period Poor quality antifreeze has poor content of corrosion preventive The content further becomes less potent with the dilution of water Choose additive that will not have any adverse effects on the materi als of the cooling system Never mix different additive as it may cause chemical reactions and therefore malfunctions WATER BOILER A water boiler can be connected to the engine coolant c...

Page 48: ...iller cap 6 Check the coolant level in the recovery tank if fitted It should lie between the Min and Max mark of the recovery tank Add clean water if necessary NOTICE The Min and Max level indicated on the recovery tank if fitted does not indicate the correct level of coolant Draining the coolant circuit 1 Stop the engine and remove the key from the panel 2 Put a container under the drain plug to ...

Page 49: ...that the drain plugs are properly tightened 3 Add coolant through the heat exchanger filler port to the correct level I CAUTION If a boiler is connected to the engine follow the filling proce dure given by the manufacturer of the boiler If the boiler is above the engine in the boat first fill the heat exchanger the boiler and top up with coolant the recovery tank located above the boiler Make sure...

Page 50: ... system should be drained Siphon breaker I DANGER Close the sea cock before any operation on the siphon breaker NOTICE The use of a siphon breaker is mandatory if the exhaust elbow is under the waterline at full load or at less than 200 mm above it A siphon breaker is mandatory in all Sail Boat and when there s a risk of water entry in the engine The siphon breaker prevents raw water entry into th...

Page 51: ... correct position in case of rein stallation 5 Carefully remove the impeller using an extractor 6 Inspect the impeller Check for damaged cracked broken miss ing or flattened vanes Change the impeller if it is damaged Clean and drain the raw water system if parts of the impeller are missing 7 Inspect the cover and the gasket for corrosion or damage Change it if they are damaged 8 Lubricate the insi...

Page 52: ...ll the components and open the sea cock Start the engine and check for leaks NOTICE When the boat is out of water check that the through hull is not obstructed by mud or algae Raw water system Draining I WARNING It is highly recommended to carry out these operations when the boat is laid up on land If the boat cannot be removed from the water close the sea cock and prevent water entry by any means...

Page 53: ...in the vicinity of the engine the propel ler and the exhaust outlet Put the lever in neutral and start the engine 5 Let the engine run few minutes at idle Add fresh water in the container if necessary 6 Stop the engine 7 Fill the container with engine coolant mix 50 clean water 50 anti freeze 8 Start the engine and let it run at idle Add enough coolant to fill the raw water system with coolant 9 S...

Page 54: ...p pears Tighten the cable terminals and lubricate them with appropriate grease Fuses The engine electrical system is protected from electrical overload damage by fuses If the electrical system does not work the engine does not start or the instruments panel don t oper ate a fuse may have trip Investigate the cause before reset ting the fuse Always have spare fuses on board Replace a blown fuse wit...

Page 55: ...to the POSI TIVE TERMINAL of the battery and then the NEGATIVE Use distilled water to top up the electrolyte level Follow in priority the battery manufacturer instruc tions for topping up If the battery electrolyte level is not adjustable maintenance free battery type do not use or charge the battery if the fluid level stands below the lower limit level When adding electrolyte unscrew the vent plu...

Page 56: ...n the pump and the alternator Visually check the belt for exces sive wear frayed cords etc If any defect has been found change the belt Check that it fits properly in the pulley Belt is constantly tensioned by an automatic belt tensioner To change the belt 1 Stop the engine and remove the key from the panel 2 Move the tensionner clock wise using a wrench and remove the belt 3 Install the new belt ...

Page 57: ...rature 25 C When cruising at high speed or when there s a strong current Important relation difference between the cathode and anodic surfaces Anodes in magnesium or zinc are generally used to protect the boat against galvanic corrosion Due to their intrinsic nature these anodes will wear down in place of other metallic components During the first year of use check the anodes deterioration every 3...

Page 58: ...r Shore power units must be in tended for marine usage All equipment fitted with a protec tive ground terminal the engine along with the anodes must be connected to the common ground of the boat I DANGER For engine with a two pole electrical system the negative pole of the battery must never be connected to the common ground of the boat I CAUTION The Sail Drive model SP60 is electrically isolated ...

Page 59: ...n 6 If more than 50 of the anode has been used up change it along with the seal The length of a new anode is 16 mm I CAUTION Screw the anode cap back on tightly and do not forget to re open the sea cock Mercathode system STERN DRIVE VERSION ONLY The Mercathode system protects the stern drive against corrosion The Mercathode system is made of a controller located near or mounted on the engine and o...

Page 60: ...n all water in the seawater circuit Long term storage procedure Complete the nearest periodic maintenance inspections and op erations before performing the long term storage procedure 1 Drain and change the engine and transmission oil 2 Change the engine oil filter 3 Change the fuel filter and pre filter 4 Run the engine to normal oper ating temperature 5 Stop the engine and take the boat out of w...

Page 61: ...nal 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 sea water 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 Check the condition of hoses a...

Page 62: ...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 White exhaust smoke 4 5 23 25 High fuel consumption 4 7 14 15 16 19 20 22 28 The engine overheats coolan...

Page 63: ... in neutral 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 o...

Page 64: ...Air intake Turbo Intercooler Compression ratio 15 1 Idle speed clutch disengaged rpm 700 Rated engine speed Max power rpm 3600 Max RPM at wide open throttle rpm 4000 Recommended cruising speed rpm 2880 3240 Weight without gearbox kg 350 Valve clearance engine cold in take mm 0 20 0 30 Valve clearance engine cold ex haust mm 0 35 0 45 Direction of rotation view from flywheel Counter clockwise TECHN...

Page 65: ...bar 1800 maxi Specific fuel consumption g kWh at wide open throttle 235 Fuel requirements EN 590 ASTM D975 No 2 D Never use fuels that have sulfur content greater than 1 0 LUBRICATION SYSTEM Oil quality API CF Oil viscosity temperate climate SAE 15W40 Engine oil capacity no engine incli nation litre 7 4 Min oil pressure at rated rpm bar 4 5 COOLING SYSTEM Coolant capacity no engine inclina tion li...

Page 66: ......

Page 67: ...NANNI INDUSTRIES SAS 11 Avenue Mariotte Zone Industrielle 33260 La Teste France Tel 33 0 5 56 22 30 60 Fax 33 0 5 56 22 30 79 Email contact nannidiesel com www nannidiesel com P N 970316242 022016 IndB ...

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