Nanni N5.160 CR2 Operator'S Manual Download

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NANNI MARINE ENGINE

OPERATOR MANUAL

DGBXXT090013

ENGINE

N5.160 CR2
N5.180 CR2
N5.200 CR2
N5.230 CR2

Summary of Contents for N5.160 CR2

Page 1: ...NANNI MARINE ENGINE OPERATOR MANUAL DGBXXT090013 ENGINE N5 160 CR2 N5 180 CR2 N5 200 CR2 N5 230 CR2...

Page 2: ......

Page 3: ...CHANGES TRACKED CHANGES CODE INDEX DATE INITIALS NATURE OF TRANSLATIONS PAGES DGBXXT09013 05 2019 MC Create Please note all changes and pages associated For further clarity please add a line in front...

Page 4: ......

Page 5: ...OST PROTECTION WINTERIZATION 16 LIVE WITH SAFETY 16 PREVENT ACCIDENTS 16 S03 FLUIDS 17 SUMMARY 17 FUELS 18 DIESEL FUEL 18 SULPHUR CONTENT 18 WINTER DIESEL 18 WATER IN FUEL 18 MICROORGANISMS IN FUEL 18...

Page 6: ...T SYSTEM 58 ENGINE MOUNTS CHECK 58 AIR INTAKE 59 CHECK THE AIR FILTER 59 CLEANING THE AIR FILTER 59 VENT CRANKCASE FILTER 60 REPLACING CRANKCASE VENT FILTER 60 FUEL SYSTEM 61 DRAIN WATER IN FUEL PREFI...

Page 7: ...perating procedures Contact a NANNI INDUSTRIES S A S authorized dealer for the servicing of your engine A list of dealers is available on our website www nannidiesel com Read this Manual carefully to...

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 i...

Page 9: ...AFE ILLUMINATED WORK AREA 12 PROPER LIFTING EQUIPMENT 12 NOISE PROTECTION 12 GENSET OUTPUT GENERATED POWER 12 GUARDS REQUIREMENTS 12 STAYING CLEAR OF ROTATING DRIVELINES 13 PAINT REMOVAL BEFORE HEATIN...

Page 10: ...tion 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 gens...

Page 11: ...efers 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 c...

Page 12: ...tal 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...

Page 13: ...ures 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 c...

Page 14: ...ors 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 re...

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...

Page 16: ...EVENT 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 vol...

Page 17: ...E 19 OILS RECOMMENDED OR AUTHORIZED 19 GENERALITIES 19 OILS VISCOSITY 20 CORRESPONDENCE BETWEEN API AND ACEA OILS 20 COOLANTS 21 COOLANT DRAIN INTERVALS 21 WATER PROPERTIES 21 WATER PROPERTIES TO MIX...

Page 18: ...re geographically available Generally speaking summer diesel fuel complying with EN 590 is usable down to a temperature of 0 C 32 F and the winter formulated fuel down to a temperature of 20 C 4 F typ...

Page 19: ...of impurities into the engine during filling or topping up be sure to thoroughly clean the filler inlet hole first and use a container free of any contamination OILS RECOMMENDED OR AUTHORIZED It is ne...

Page 20: ...owards oxydation and fuel economy Refer to the expertise of the local Nanni Industries representative regarding the oil that best suits your engine CORRESPONDENCE BETWEEN API AND ACEA OILS API ACEA JA...

Page 21: ...ethylene glycol and propylene glycol base coolants together Do not mix coolants of various brands and makes together Do not use coolants containing nitrites WATER PROPERTIES TO MIX WITH COOLANT CONCEN...

Page 22: ...e glycol or 60 propylene glycol Refer to the table below Ethylene Glycol Freeze protection limit 40 24 C 12 F 50 37 C 34 F 60 52 C 62 F Propylene Glycol Freeze protection limit 40 24 C 12 F 50 37 C 34...

Page 23: ...hem Wear gloves and eye protection glasses Follow all safety rules Wait for engine to cool down Do not let waste to drip on the ground down a city drain or into any water source Improperly disposing o...

Page 24: ...glycol dm3 litre 9 11 12 14 15 30 12 14 16 18 20 40 15 18 20 23 25 50 18 21 24 27 30 60 21 25 28 32 35 70 24 28 32 36 40 80 27 32 36 41 45 90 30 35 40 45 50 100 33 39 44 50 55 110 36 42 48 54 60 120...

Page 25: ...e can be exhaust emission certified It means that Nanni guarantees that all engines of the same type that are manufactured are approved and certified by the authorities in accordance with different ex...

Page 26: ...o comply with the warranty conditions will void the Warranty The validity of the Warranty is also dependent on proper installation and maintenance operation being carried out by an authorized Nanni re...

Page 27: ...S The U S EPA and CARB prohibit the removal or render ing inoperative of any device or element of design in stalled on or in engines equipment in compliance with applicable emission regulations prior...

Page 28: ...E 30 BATTERY CHARGE 30 PREHEATING 31 ENGINE OIL PRESSURE 31 WATER IN THE FUEL FILTER 31 C4 PRO PANEL 31 C5 PANEL 32 C5 STANDARD SEPARATE INSTRUMENTS 32 C5 OPTIONAL SEPARATE INSTRUMENTS 32 C5 TACHOMETE...

Page 29: ...on the Flying Bridge deck As a good practice code the main panel is fitted with a key switch located in the wheelhouse and used to prevent unauthorized starting from the secondary panel To start the e...

Page 30: ...NGER Never open the coolant filler cap or any plug of the cooling system when the engine is warm Steam or hot fluid can spray out CAUTION If this alarm comes ON while operating the engine stop the eng...

Page 31: ...the engine exept in extreme emergencies and check the engine oil level and the oil filter condition To operate an engine when oil pressure is too lowcan lead to a severe engine damage Do not operate...

Page 32: ...uments manual C5 TACHOMETER LCD DISPLAY The analog tachometer displays the engine speed Multiply the value by 1000 to get the revolutions per minute of the engine See the example below ALTERNATOR CHAR...

Page 33: ...is alarm comes ON while operating the engine stop the engine exept in extreme emergencies Wait for the engine to cool down Check the coolant level the belt condition the raw water filter and if the se...

Page 34: ...ertain The maximum engine speed allowed when the drive is in the beach range is of 1000 rpm Sector 3 is used to completely lift the propeller drive unit when towing the boat Never start nor run the en...

Page 35: ...12 V X X X X X X X X X C4 C4 12 V X X X S S S S S C4 12 V C4 24 V X X X C4 loose instr X X X X X X X X C4 loose instr C4 w o key X X X X X X X X C5 Pleasure CAN 10B C5 Pleasure CAN 5B C5 Pro CAN 10B C...

Page 36: ...4 24 V C4 loose instr C4 loose instr X X X C4 w o key C5 Pleasure CAN 10B X X C5 Pleasure CAN 5B X X C5 Pro CAN 10B C5 Pro CAN 5B X X C5 Fly loose instr X X X C5 loose instr S S S C5 loose instr indic...

Page 37: ...37 S06 COMPONENTS SUMMARY SUMMARY 37 S06 COMPONENTS 38 ENGINE MAIN COMPONENTS 38 ENGINE VIEWS N5 CR2 39...

Page 38: ...COMPONENTS 1 Alternator 2 Alternator Belt 3 Belt cover 4 Starter 5 Air filter 6 Fuel filter 7 Fuel injection pump 8 Heat exchanger 9 Heat exchanger drain plug 10 Raw water pump 11 Raw water pump filte...

Page 39: ...39 S06 COMPONENTS ENGINE VIEWS N5 160 CR2 N5 180 CR2 N5 200 CR2 N5 230 CR2 18 17 5 16 6 12 13 15 3 4 12 19 7 20 21 2 1 14...

Page 40: ...40 NOTES...

Page 41: ...R OPERATION 43 ENGINE START 44 ENGINE STARTED 46 STARTING WITH BOOSTER BATTERIES 46 ENGINE RELUCTANT TO START 46 IDLING ENGINE 46 NORMAL ENGINE OPERATION 47 BREAK IN 47 POWER TAKE OFF 47 REMOTE CONTRO...

Page 42: ...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...

Page 43: ...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...

Page 44: ...perature to preheat the engine POSITION 1 POSITION 1 2 preheating POSITION 2 5 Press fully to start the engine position 2 Once the engine has started release the button all lamps go out POSITION 1 POS...

Page 45: ...w water flows from the exhaust outlet at the hull If the water does not flow stop the engine and check the raw water level Electronic type 5 Turn the ignition key to the ON position It is not required...

Page 46: ...for few minutes to charge the battery 4 Stop the engine and remove the cables in the exact reverse order from installation ENGINE RELUCTANT TO START If a water lift water lock muffler is installed on...

Page 47: ...sual noise or vibration Sudden loss of power Excessive black exhaust Excessive fuel consumption Excessive oil consumption Fluid leaks BREAK IN Operate the engine with care for the first 50 hours of op...

Page 48: ...void violent manoeuvres or unexpected speed changes while sailing People can fall over or overboard Keep also in mind that the weight distribution passengers equipments etc inside the boat has an impa...

Page 49: ...ating temperature regularly Run the engine at full throttle regularly in order to burn off any possible deposits in the fuel system S07 STARTING RUNNING MANOEUVRING WARNING Shifting at high speed can...

Page 50: ...e propeller below its speed when the engine is at idle The boat speed is reduced by 30 to 70 CAUTION The Trolling valve system must never be used for manoeuvring It also must never be used at an engin...

Page 51: ...The engine stops Turn the key of the main panel counter clockwise All indicators will turn off AFTER STOPPING THE ENGINE CAUTION Even after the engine has stopped some components and fluids will remai...

Page 52: ...d before the next time the boat is used 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 sys...

Page 53: ...VERVIEW 65 COOLANT 66 COOLANT LEVEL 66 DRAINING THE COOLANT CIRCUIT 67 COOLANT FILLING 67 REMOVING AND INSTALLING THERMOSTATS 68 TESTING THERMOSTATS 68 RAW WATER SYSTEM 70 CHECKING SACRIFICIAL ANODES...

Page 54: ...r if 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 technician...

Page 55: ...OLE ENGINE Engine Mounts Inspection 4 years Engine Alignment When Mount Replacement Hoses Clamps tightness Bolts Nuts Tightening Visual Inspection Coolant fuel oil exhaust raw water leaks Valve Cleara...

Page 56: ...maintenance Watch for any oil or fluid drop as it is an evidence of a leak somewhere CAUTION Do not let oil fuel or grease deposits build up around the engine as they may increase the risk of fire in...

Page 57: ...ble 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 en...

Page 58: ...ight or change them if necessary Check for carbon or soot deposits on exhaust components as it is a conclusive sign of an exhaust leak Should any defect appear on any item of the exhaust system replac...

Page 59: ...970317078 Kit Air filter cleaner FR IT DEU Long life NANNI air filters require periodic cleaning Maintenance of these air filters is very simple Please follow the 4 steps below Cleaning Spray liberall...

Page 60: ...en fabric to avoid introduction of flint in the engine REPLACING CRANKCASE VENT FILTER The top of the crankcase filter is equiped with a sensor poping up when the filter is full and needs to be replac...

Page 61: ...check for leaks FUEL SYSTEM DANGER Stop the engine and let it cool down before refuelling or carrying out any operation on the fuel system CAUTION Fuel is flammable and can be dangerous Fuel spilled o...

Page 62: ...new primary fuel filter seal with thin film of clean fuel 10 Screw primary fuel filter into header until the seal contacts the fuel filter header 11 When seal contacts the fuel filter header tighten...

Page 63: ...ngine and transmission oil level before starting the engine The oil level should be within the range indicated on the dipstick between the Mini and Maxi level HOW TO CHECK THE OIL LEVEL 1 Pull off and...

Page 64: ...HE OIL FILTER Replace the oil filter every time the engine oil is drained 1 Remove the oil filter A with a filter wrench tool Turn the filter counter clockwise CCW Remove the gasket 2 Apply clean engi...

Page 65: ...anger when the en gine reach the appropriate temperature of the engine Principle of operation of water cooling with heat exchanger on an engine External keel cooling principle CAUTION Engines designed...

Page 66: ...ing the internal temperature is high as a result the coolant liquid expands its volume The heat exchanger is designed to accomodate this normal and physical expansion Make sure not to overfill the hea...

Page 67: ...heat exchanger For Keel Cooling system or when using a water boiler the coolant capacity must be adapted according to the pipes length and the tank capacity HOW TO FILL THE COOLANT SYSTEM 1 Check that...

Page 68: ...rmostat cover with O ring cap screws washer and nut Tighten nut and all cap screws to the following specifications 35 Nm 25 lb ft TESTING THERMOSTATS 1 Remove thermostats 2 Visuallyinspectthermostatsf...

Page 69: ...Remove heat exchanger core H through rear side of housing 10 Remove remaining end cap from water manifold heat exchanger housing Remove end cap from heat exchanger core 11 Thoroughly clean all buildup...

Page 70: ...ntervals Zinc plugs new part dimensions are 31 8 mm 1 25 in long and 9 5 mm 0 38 in diameter SIPHON BREAKER DANGER Close the sea cock before any operation on the siphon breaker NOTE Siphon breaker its...

Page 71: ...e and thighten cap screws to specifications 140 Nm 103 lb ft TO REPLACE THE SEA WATER PUMP IMPELLER 1 Remove cap screws and cover plate A from sea water pump 2 Remove impeller B from pump housing 3 Re...

Page 72: ...nd check for leaks 5 Notice When the boat is out of water check that the through hull is not clogged by mud or algae S08 MAINTENANCE RAW WATER SYSTEM DRAINING WARNING It is highly recommended to carry...

Page 73: ...als are still present consult your Nanni representative Do not add up cleaners additives like caustic soda as aluminium parts are prone to fast corrosion if harshly cleaned 8 Clearly identify all clos...

Page 74: ...g Never disconnect the cable between the alternator and the battery when the engine is running WIRES AND CONNECTORS Check that electrical wires and connectors are dry and in goodcondition Replaceanyde...

Page 75: ...Yellow Red Start Circuit Relay G Black Start Circuit Relay H Red Start Circuit Relay J Red Fuse Holder K Black Ground L Light Blue Oil Sender M Black Oil Sender N Red Starting Motor O Red Starting Mot...

Page 76: ...tor B 20 Amp Fuse with Holder C Start Circuit Relay D Fuel Filter Water Separator E Starting Motor F Fuel Shut Off Solenoid G Battery H Tachometer Pick up I Coolant Temperature Sensor J Engine Oil Pre...

Page 77: ...77 S08 MAINTENANCE INSTRUMENTS PANEL...

Page 78: ...age drops premature discharging notably in wet or cold weather In some occurances these disturbances may be hard to locate Use a brass brush to clean battery terminals posts DISCONNECT THE STARTER CAB...

Page 79: ...of adding electrolyte If the battery electrolyte level cannot be adjusted maintenance free battery type do not use or charge the battery if the fluid level is below the lower limit level If the batter...

Page 80: ...lt tensioner is designed to operate within the limit of arm movement provided by the cast stops A and B when correct belt length and geometry is used Visually inspect cast stops A and B on belt tensio...

Page 81: ...ANEOUS CAMSHAFT TIMING From the two camshafts down to the crankshaft N5 160 engine timing is ordered through a gear system The complete assembly is service free Inspection is occuring only during a ma...

Page 82: ...82 S09 STORAGE SUMMARY Table des mati res S09 STORAGE 82 SUMMARY 82 LONG TERM STORAGE 83 LONG TERM STORAGE PROCEDURE 83 RESTARTING THE ENGINE 84 BATTERY 84...

Page 83: ...ge 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 c...

Page 84: ...sary 10 Connect fully charged batteries 11 Check the anodes 12 Install the propeller 13 Check the operation of the control cables and their condition 14 Check belts Adjust the tension 15 Bleed the fue...

Page 85: ...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 uneve...

Page 86: ...top 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 dama...

Page 87: ...njection directe Rampe commune R gulation lectronique Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational dir...

Page 88: ...Fuel consumption propeller load exp 3 l h 3 3 5 3 7 9 11 8 17 6 23 2 30 7 34 gal US h 0 9 1 4 2 1 3 1 4 7 6 1 8 1 9 Consommation de carburant pleine charge Fuel consumption at full load l h 12 2 15 6...

Page 89: ...pression maxi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 075 inH O 0 3 Temp rature d chappement maxi Maximum exhaust temperature C 441 F 825 8 SYSTEME D...

Page 90: ...d marrage froid minimum Battery minimum cold start current kW 3 7 CCA 640 Batterie recommand e K20 Recommanded batterie K20 A h 160 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without trans...

Page 91: ...njection directe Rampe commune R gulation lectronique Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational dir...

Page 92: ...Fuel consumption propeller load exp 3 l h 3 3 5 1 7 9 11 7 16 9 23 2 30 1 37 9 gal US h 0 9 1 4 2 1 3 1 4 5 6 1 8 10 Consommation de carburant pleine charge Fuel consumption at full load l h 12 4 15...

Page 93: ...pression maxi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 075 inH O 0 3 Temp rature d chappement maxi Maximum exhaust temperature C 438 F 820 4 SYSTEME D...

Page 94: ...manded batterie K20 A h 160 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 578 lbs 1274 3 CONSEILS D INSTALLATION INSTALLATION TIPS Diam tre tuyau alimentation carburant...

Page 95: ...njection directe Rampe commune R gulation lectronique Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational dir...

Page 96: ...rant charge exp 3 Fuel consumption propeller load exp 3 l h 3 3 5 7 8 4 11 7 16 22 30 39 5 45 3 gal US h 0 9 1 5 2 2 3 1 4 2 5 8 7 9 10 4 12 Consommation de carburant pleine charge Fuel consumption at...

Page 97: ...pression maxi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 075 inH O 0 3 Temp rature d chappement maxi Maximum exhaust temperature C 423 F 793 4 SYSTEME D...

Page 98: ...mmanded batterie K20 A h 160 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 578 lbs 1274 3 CONSEILS D INSTALLATION INSTALLATION TIPS Diam tre tuyau alimentation carburan...

Page 99: ...njection directe Rampe commune R gulation lectronique Direct injection Common Rail Electronically controlled Ordre d allumage Firing order 1 3 4 2 Sens de rotation vue c t volant moteur Rotational dir...

Page 100: ...ge exp 3 Fuel consumption propeller load exp 3 l h 3 2 5 2 8 5 11 7 16 2 22 28 6 39 5 49 9 gal US h 0 8 1 4 2 2 3 1 4 3 5 8 7 6 10 4 13 2 Consommation de carburant pleine charge Fuel consumption at fu...

Page 101: ...ession maxi admissible dans le circuit d chappement Permitted back pressure in the exhaust line bar 0 075 inH O 0 3 Temp rature d chappement maxi Maximum exhaust temperature C 415 F 779 SYSTEME D ADMI...

Page 102: ...commanded batterie K20 A h 160 POIDS A SEC DRY WEIGHT Poids sans transmission Weight without transmission kg 578 lbs 1274 3 CONSEILS D INSTALLATION INSTALLATION TIPS Diam tre tuyau alimentation carbur...

Page 103: ......

Page 104: ...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 nannidiesel com...

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